Material for making templates?

[Klara]

Problem is, I live in France. Ordering from the US involves shipping, customs, time. Whereas Ikea is under 2 hours away, I need a new kitchen knife anyways and am thinking about a new bed...

So I'm looking forward to your review, @MtlBiker !

Edited May 17, 2021 by Klara

[erhana]

9 hours ago, MtlBiker said:

I see that was your first post on this board... Welcome!!!!

Thanks for the welcome. In fact, I have become a frequent visitor of this forum for a couple of years, but this was the first time that I had something to contribute. So I registered  to post on this subject.

Laser cutting acrylic sheets is mainly a sign making industry's thing here where I live, and I can easily access several shops to submit the DXF files of my designs. I don't think there would be a shortage of this kind of shops around the world.

But as I said earlier, this method requires CAD files to be generated. As someone else in this conversation also stated, I strongly advise entering to the CAD realm at the simplest level. There are several 2D CAD software both free and easy to use.

[JamesR]

I use 1/8" masonite with a checker patterned back. It is easier to cut then 1/4" and it does not slip around so much.

[MtlBiker]

3 hours ago, Klara said:

Problem is, I live in France. Ordering from the US involves shipping, customs, time. Whereas Ikea is under 2 hours away, I need a new kitchen knife anyways and am thinking about a new bed...

So I'm looking forward to your review, @MtlBiker !

Problem is, I live in Canada.  Ordering from the US involves shipping, customs, time.... 

So I know exactly what you're talking about.  But unlike you, I'm lucky that Ikea is actually along my route to work and only about 15 minutes away.  I should be there in a couple of hours.

 

[MtlBiker]

1 hour ago, JamesR said:

I use 1/8" masonite with a checker patterned back. It is easier to cut then 1/4" and it does not slip around so much.

I'm using 1/8" masonite but it's smooth on both sides.  I haven't seen (here in Canada) masonite with a patterned back.  I always put weights on my template before cutting my material and as long as I'm careful, the template doesn't move out of place.

 

[JHLeatherwood]

13 hours ago, MtlBiker said:

<snip>

I agree that laser cutting would be ideal, but I've never dealt with any company that does it, and I wouldn't know where to start.  It would certainly cost more than my other options although if I was doing really large quantities, it would probably be better.

Most likely I would be cutting the material on my scroll saw... I have different blades, including a couple specially for plastics, and I could always heat treat the edges for smoothness.

<snip>

I read RockyAussie's excellent introduction to laser engraaving/cutting, bought the parts and pieces, and learned to use it over a weekend.

Not for production (as in, producing templates for sale), but I really like my little eleksmaker A3 Pro diode laser and cheap Amazon acrylic. The laser cutter/engraver handles sizes up to 30x40 CM, but has pass-through under the frame so larger sizes (in one dimension) are possible. You can also index the pieces, as Maker's Leather Supply does with their pistol caddy templates. You can also engrave the template name, instructions, etc. right on the template for future reference.

If you can tolerate the wait and uncertainty, you can get the eleksmaker from alibaba for cheaper (<$300 US complete with laser), and the 12x12 in acrylic sheets are only about $10 each.

Yes, it takes a LONG time to cut (low power diode means n hour or more to cut out a card wallet template) and some experimentation to get the design to cut as desired, but I can draw up, troubleshoot, and test cut (on cardboard), a complete wallet template after dinner, and run the cut the final piece the next night after dinner (so <8 hours total).

This is a hobby for me - if I wanted to go faster, I'd consider a 50 watt CO2 laser cutter and get the same template cut in 15 minutes (for about $1000 US all in with cooler, air assist, exhaust filtering, etc.)

Alternatively ... my local woodworking store (Woodcraft) has a large bed (36x24in) 75W laser cutter - you can take them a cut-ready file and they'll cut it for the cost of materials + a per-minute charge, or they'll take your image/design and make it cut-ready for a small fee.

 

 

 

[MtlBiker]

Back from my shopping trip to Ikea...  I bought three different mats, and I think two of them would work well for making templates I can cut against, while the third one, largest and most expensive I suspect won't work.  It's made from LD PE (Low Densitity Polyethylene) and I'd tried cutting another piece of that I had last week, and found it splintered/shattered when cutting.  So I doubt it will work.  But I'll try.  Here's what I bought:

KOLON - 39 1/2" x 47" - 1.75mm thick - $29.99 - made from LDPE - probably will shatter/splinter when cutting

SKVALLA - 15" x 23" - 1.6mm thick - $4.99 - unknown flexible plastic of some kind, think it will cut well.

PLUGGHAST - 17 3/4" x 25 1/2" - 2.5mm thick - $5.99 - unknown flexible plastic, with a pattern and less transparent than the others

(All prices Canadian dollars.)

I think the PLUGGHAST is going to turn out the best for making templates.  Thicker, most likely fairly easy to cut to shape, but I'll be cutting them all tomorrow to see how they work.

Here's what the pieces look like:  The big one is the KOLON, at the right with the pattern is PLUGGHAST and center is SKVALLA.  The smaller white rectangle at the upper left is just the stuck on label on the other side.  By the way, the KOLON floor protector mat has very small bumps on the bottom side, I guess to keep it from shifting on a carpet.  I don't think those would be a problem but it could always be used with the bumps face up on the fabric.  Just don't think it will cut well.

 

[fredk]

extra info.

The UK Ikea site gives some details of what these are made from

 SKVALLRA consists of 75% of plastic made from sugar cane and 25% traditional plastic. 

KOLON is PET plastic and Polyurethane plastic

PLUGGHAST is Polyethylene plastic, and EVA plastic

Edited May 17, 2021 by fredk

[Klara]

@MtlBiker Thanks a lot for the review! 

[MtlBiker]

Just a little follow-up.....

I cut some templates out of the PLUGGHAST material and it cuts very easily.  I did the straight sections with a utility knife and the curves on my scroll saw (because I find it easier to follow a curve with it).  And last night I cut a bunch of fabric using the template to cut against with my rotary cutter.  I found my 60mm cutter worked better than my 45mm.  Worked like a charm!  With just a little care, I didn't cut into the template with the rotary cutter.  Much more durable than paper, card stock or even matboard.

For me that material is a winner.