I want to make some Epoxy molds, and part of the mold needs to have modestly small, accurate holes bored in it. In particular, the mold needs to have some 0.3060" -0.0007/+0.0007 holes bored in it. Obviously, the holes need to be reasonably smooth so the mold will easily release the Epoxy when cured. The mold seam will be radial to the hole axis, so a little mold release should easily accomplish this as long as the milling marks are not too deep. This should not be a major challenge. The holes also will not be very deep - perhaps 1/2" at most. The big challenge is coming up with a tool to handle the work. I don't think there is a reamer this size, is there? I certainly do not have any boring bars small enough to bore a hole this size, especially since my boring head uses 3/4" shank boring bars.
I have not yet decided on the material I will use for the molds - probably Aluminum, but I have not ruled out acrylic or polycarbonate. In any case, the machining itself won't be challenging for any reasonably hard tool material.
I have not yet decided on the material I will use for the molds - probably Aluminum, but I have not ruled out acrylic or polycarbonate. In any case, the machining itself won't be challenging for any reasonably hard tool material.
