on my face plate I need a square removed for my led display

[NickLatech]

this could be considered off topic.

I need a small .25x.25 inch square removed from my aluminum face plate. I want it to be a clean cut. I tried using a drimel tool, but I didnt the lines as straight as I wanted.

Anyone have any ideas on how to get it removed?

Thanks
Nick

[newguy]

Use a very sharp x-acto knife (scalpel) and a straight edge to mark the edge of the square hole. Then go to work with a file. Use a flat file, and use the biggest file you can fit in the hole (slightly less than 0.25").

I've cut rectangular holes for LCDs in this manner, and it works very well. Takes a long time, but works well.

Because square holes are such a pain to cut, I now use circular holes whenever possible. It's much easier to creat a circular hole using a drill than it is to cut a square hole by hand.

Something like this is too fine for a dremel. You can use the dremel to rough out the opening, but you really have to use a file to finish it off.

[SherpaDoug]

.25" x .25" is kind of small. I would try a 1/4" drill followed by filing. If it was a little bigger you could use a nibbling tool like GC395-ND at Digi-Key.
_________________
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[NickLatech]

I was ran across an item called a panel punch. I havnt used one but they look like they could work nicely.

Nick

[rberek]

Most of the panel punches I've seen are for larger (i.e. 7/16" and up) holes, but if you've found a smaller one, please let me know. They've also got some nice punches for DB9/DP25 connectors, but they're $250+ . Nice if you've got a product rather than a prototype to build.

[NickLatech]

this so for a small production run.. So if the cost matches the quality, I wouldnt mind spending some dollars

Nick

[jecottrell]

Try laser cutting. I just had several things done and price is about $100 minimum and just slightly more for each additional piece. I had 2 complex faceplates cut in 0.125" aluminum and it was just over $100 total.

http://www.themetalman.com/home_laser.html

A DXF file is all you need to get going.

John

[MikeValencia]

On one of Circuit Cellar magazine's ads, i found www.protocase.com

You can download their super easy CAD tool, and with it draw any shape of cutout you want and spend $100+ for a few prototypes.

There's also frontpanelexpress.com

I haven't used either though.

[jecottrell]

Mike,

I had tried one of those and the price was about $250 for one piece! That's when I went local.

John

[NickLatech]

i found a panel punch from mouser for $51 part #380-0126

[DOMachining]