This is ideally part one of many build logs of a LADAR prototype. The first version had some weight, vibration, and power issues, so this is an attempt to make a fix for those.
Without a laser cutter or CNC Mill, I was looking to get a general idea before spending on outside machining. I pulled out the trusty Dremel, got some carbide bits and a diamond blade for my table saw, and got to work! (Didn’t want delamination of the CF, so high RPM and diamond/carbide tooling is best).
Next best thing to a cnc mil……kinda
Diamond Saw blades + 30,000 RPM Carbide bits = Win
I needed to make some 3″ discs out of 1/16″ Garolite and 1/32″ CF; the Dremel circle tool worked pretty well. However, the Garolite was a struggle for the Dremel – it had a hard time holding RPM even with carbide tooling and slow feed rates, but the CF was like butter! I had a shop vac taped on the table to get the dust – CF is nasty to cut, so its a must!
Also, as it turns out, Dremel makes a decent drill press add-on and some larger collets that can fit some good size drill bits, (up to a 24 wire gauge I’d guess).
Lining up the holes
Not doing this again…..
Overall, it only took four hours to do most of the printing, routing, drilling, and cutting. I still have a bit more work to do so check back for part 2!