The black forest sign is to be routed from multiple layers of 30 lb. Precision Board HDU (high density urethane). At the time we built this sign, 2" was the practical limit for layer thickness — this was on account of length of the bits we had on hand. Thus, when we started thinking about this file the first step was to decide where the layers would begin and end. This instalment will go over that process…
It is important to note that EnRoute is a robust program: it gives users many options when creating files. Often these diverging paths lead to the same place. So, you should understand that the way we completed this task is not the only way to accomplish a file like this.
The first thing we did was to create a “zero height relief” of the final shape I wanted for the crown molding. This is a relief (a surface) with no thickness — if that is a little hard to wrap your head around you can think of it as having the thickness of a piece of paper.
Next, we used the bevel tool to create a relief twice as wide as we needed. Later, we will merge it to the zero height relief that hides under it to save only the shape we need.
After this this, we created the flat, top and bottom, parts of the molding.
We like to build all of the pieces separately and then merge them to create the final shape as a last step.
Next, the egg shapes were created using the dome relief tool. Then we raised them up (in the z axis) until they were right near the top of the molding.
The rest of the sign was built in the same fashion as the top molding, one piece at a time until all was right. Then, using the “combine tool,” it all was combined together. (We kept a copy of the original vectors to add more pieces later as needed.)
The three quarter view gives us a better idea of how the sign will look when it is routed.
The inside oval (a reverse dome) will be routed from the inner layer. Also, we still have to plan for the steel structure that will go inside the sign. Space for the steel will be routed into this piece.
The sections with lettering will be routed from 1.5" HDU and glued on later.
It's almost time to put this sign on the CNC and let it do it's magic!