I have become rather fond of laser-cutting of metals.  In stainless steel, the kerf typically runs .007...010"wide, and the HAZ is present but not visible.  It's possible to cut clean holes of arbitrary shape through thick sheet with very little edge distance; i.e., you can burn holes that you just can't punch or drill.  At reduced power or higher speed, the laser can leave an indelible mark without penetrating all the way through.

I think similar work can be done in aluminum.  Set up a DXF file of things you'd like to see and send it to some laser cutting services to see what they can do.

E.g., you could cut the door from the panel, and use both, and cut a slot as thin as a DVD, and texture the surface or apply legends, all in the same step.  Start with color anodized stock.  Cut the lettering all the way through and backlight it.  Make an integral pushbutton by cutting three spirals around it.  Make multiple panels with matching finishes held together by slivers of metal that you can crack apart like they do circuit boards.  Make a structure with slots and tabs that you can insert and deform.

Let your imagination run a little.  Try a few test pieces, including things that you don't expect to work.  Sometimes you surprise yourself.

Mike Halloran
Pembroke Pines, FL, USA

Hello Mike,

Thank you for your response.  Is there a way of posting or uploading a screenshot of my design on the thread? Actually I just found a picture of it on the client's website:
http://www.modsystems.com/products/merch.html

The picture doesn't show what the faceplate looks like in the center area when the door is open, but it is recessed.  The door opens by swinging down, hinged at the bottom.

I think the laser cut sheet would be good for a 2D design or a simple 3D design, but there are bevels; rounds; and features (both inside and outside) that recess into or protrude from the faceplate.

The comment about making tabs and slots is interesting, but with the current design, it might be too much of an 'erector-set' type of assembly and there would probably be too many visible parting lines.

We were initially thinking of stamping out a thin sheet with the same form then adhering it to a plastic frame that would  have the necessary features for the interals.

Any further comments or technology suggestions are much appreciated.. By the way any good websites that go into today's manufacturing processes?

Thank you very much,
Jimmy

I'm sorry, I can't identify the faceplate you're talking about on that site.

You can make photos appear here by hosting them elsewhere and embedding a link.  There are instructions in a FAQ somewhere.  I'd prefer just the links, so my browser doesn't have to deal with photos every time it loads the page.

Mike Halloran
Pembroke Pines, FL, USA

FAQ559-1100: How Can I Show An Image In A Post

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The picture on the upper left shows a touch screen and to the left of that is the 2U rack mount device I am working on.  The client is looking for a very high-end looking faceplate.

I've done some more research on the internet and found that it's at least worth a try to have one of these electro-plated and see how it feels.  I found that I can get a brushed chrome finish and it will simulate a brushed 304 steel look.  I'm just still worried about the overall feel, e.g. cold-touch of real metal, weight feel, durability.

Any other suggestions or comments are much appreciated..

Thank you all again!

Have you thought of visiting a few trophy shops in your area?  They have all types of metal and finishes and catalogs.

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Business Site     http://mech.e.tripod.com
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Thank you all for your help.

I find this forum very useful and hope that my question was not too elementary sounding.  I did do as much research on the internet as possible before posting and also searched the forum.

Thanks again,
Jimmy

Metal's feel is best simulated with ... metal.  If you don't need sharp interior corners or detail on both faces, you can get batches of plates CNC milled from aluminum plate or sheet for relatively little cost.

Mike Halloran
Pembroke Pines, FL, USA