Audio Guide

If you are new to EMS, don't miss the Audio Guide. It the fastest most fun way to learn how to design 3D parts. The guide takes you step-by-step into the EMS world.

Designs with numerous lines

The software can get bogged down or even appears to freeze if you have too many lines in your design. This could happen, for example, with a grid of 20 x 20 (400) holes. One customer had a design with 2599 lines! Solution: specify only a few of the holes and the remainder using CTM (comments to machinist).

New release

It's been 3 months since the last update of the software. We suffered from the just-one-more-change syndrome. Details are at: http://www.emachineshop.com/download/updates.htm .

"Direct" mode of ordering

If you can't use the "direct" method of ordering or sending troubleshooting messages, it's probably due to a firewall. Click Edit Preferences Ordering Advanced and add your SMTP server.

CTM vs CTU

Some users confuse CTU (comments to user) with CTM (comments to machinist). Double check that you used the correct type of comment. For example if you put a tolerance for a hole using CTU, the machinist will not see your request.

Turret Punch

TP is economical for many jobs but remember that it uses standard punch sizes for cutting. When one or more holes in your design cannot be cut with standard punches, consider Laser Cut, Water Jet or Wire EDM.

Custom flat washers

If you ever need a flat washer of a specific OD, ID, thickness, and material you can do it easily in ems. Just draw the two concentric circles and select the material and machine. Turret Punch will be lowest cost in most cases but also consider laser or wire EDM for more size flexibility. For longer runs use Blanking.

Resetting the origin

If you did not start your design at a "clean" origin like (0,0), it's easy to correct. Press Ctrl+A to select all lines. Enter 0,0 on the numeric bar and press Enter. This will move the lower left corner to 0,0. A clean origin makes it easier to check your design without needing to use dimension guidelines.

Importing designs

When importing 3D designs from another CAD package: do the import; use edit-select all; choose Line Machine User Comments. This converts all lines to comments lines. Then assign a machine to a few lines and check the 3D view. Converting lines gradually is much easier than trying to do all lines at once.

Newsletter vs RSS feed

If you signed up for our newsletter and did not receive one there is a good reason. We've just been too busy to get a newsletter out. To stay in close touch with us look for the feed links near the bottom of the right margin. Atom and RSS feeds (two hot web tricks) allow you to see additions to this blog automatically - like a newsletter. If you don't have a feed reader click the feed links to find out where to get a reader. You can get PC-based or Web-based readers. Many feed readers are free. Say that six times fast!

Rubber molding

In addition to injection molding we recently began offering rubber molding too. Today we shipped a job of simple rubber washers (with a small recess). Rubber of course is good for sealing, flexibility, grip, shock absorbing, sound suppression, etc.

Comment lines

Some of our customers add various guidelines that provide a double check that everything is in the right spot. For example, for two holes that need to be 10 inches apart, they draw a comment line between the hole centers and leave the line in the drawing. They check that the comment line is 10 inches and that the circle centers align with the line end points. Though not necessary, such comment lines can add a level of comfort since ems drawings are normally not dimensioned.

Making a preliminary design

Before spending time doing a design in detail, do a quick rough design of the approximate desired size and shape of your part and selected material. Then run the Analyze command and make sure it passes the machinability tests. Then, as you refine the design, run the Analyze command periodically for an ongoing "reality check".

Engraving letters

Did you know you can machine letters into parts? First select the "A" button and type the text. This creates a comment. Then press the F5 key to get the machine dialog and select a machine. We now include fonts tailored to some common machines. For example, for laser you don't want the hole in the letter P falling out! So all internal contours are attached to the outside.

Plating & Anodizing contacts

During electroplating and anodizing etc, electrical contacts must be attached to the part. At the connection point there can be small marks where plating does not occur. Today a customer commented on this in a decorative job. To avoid this we recommend to use CTM (Comments To Machinist) to clarify which surfaces are visible and must be free of contact marks. For example, if there is a hole thru a part with a top and bottom surface the normal process is to hang the part on a wire thru the hole. But if you specify that the top must be free of contact marks, we will arrange a different mechanical attachment method.

Metal business cards & photo etching

Our photo etching is working well. Stainless steel eraser shields are a common example of this process. You can get very fine detail on thin metal. If you really want to stand out at a business conference (or bar) hand out your stainless steel business card with text cut thru it. One customer used the process for a special paint shield. I have also seen delicate sculptures done this way in a gallery in Soho NYC.

Metal enclosures

We finished fab of a metal enclosure today only to find the two pieces don't fit. The reason? Invalid customer design. Be sure to use Tools Create Box and the Model Bends command to check your design to avoid this scenario. And when you use the Model Bends command slide the parts together and look at the fit under magnification.

Injection Molding Tip

Although the IM interface is based on the Mill and we do not allow multiple parts in one Mill job, IM is a bit different - you can link two parts together by connecting them with a small channel in many cases. That will save some $$$. But don't go nuts with this - today we got an order with 17 parts interconnected!

Chapter in book

Yesterday was interesting. I met with a gentleman writing a book on how to make stuff. He liked our concept enough that he plans to add a full chapter on ems. I gave him the scoop, took him to lunch, did my ten cent demo and he was raring and ready to write. I'll keep the blog updated on this developes.

Too many orders

Yesterday we had so many jobs in QC we ran out of table space. But don't worry - keep those orders coming - we can order more tables ;-)

Taking the blog blunge (aka plunge)

Not easy running a business these days. Web sites. Email. Management. Customers. Customers. Customers. And now Blogs. Well, what's one more complication. And what are weekends for anyway. Here I plan to give a bit of the inside scoop, show some pix of cool parts, give some clever tips, etc. Here goes ...