I received a request from a customer to assist with the design and manufacture of mechanical enclosures for a Microwave Frequency Conversion product. I used to work in Microwave Comms industry and was able to use my previous skills to help.
I used Solidworks to design everything including the fitting of PCBs into my designed housings. I also laid out the various modules on to two 3mm plates so that inputs and outputs were easily connected with semiflex cable and all modules accessible.
HSMXpress was used to program all milling operations. Mach3 is the motion control program I use to operate my small Syil X3 CNC Mill. The mill is small and not very rigid, so small cuts are the order of the day. Because I do not have tool changing capability, I try to use only one toll to perform roughing and finishing. The enclosures had R3 radii in the internal corners and 7.5mm gaps between internal and outer walls, so the maximum size cutter I could use was Ø6.
I am very pleased with the results and especially HSMXpress.
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