Testing the ‘pixel’ mirror cuts and making more facet blanks

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Projection test from pixelated mirror. ‘Pixel’ size was too small (1mm square), causing too much light scatter and therefore breaking up the image.

I tested the ‘pixel’ cut facets with a series of images, but the resulting projected images were disappointing. The size of the top of each of the ‘pixel’ profiles relative to the angle between them (as one profile cut steps down to the next profile cut) was too small. I discussed this with Geoff and we decided to try a few more tests with slightly larger ‘pixel’ sizes. I had designed the original tests to be 1mm square, we decided to increase this to 1.5 mm square and see what happens to the projected image with these profiles. I will post the outcomes these tests are complete.

Deirdre preparing the lathe to cut the ‘pixel’ patterned  facets. Here I am calculating the ‘trigger’ points on the tip of the diamond tool (using the camera) to locate the centre point of the tool relative to the x-axis and centre of the part being cut.
Deirdre locating the ‘trigger’ points on the tip of the diamond tool (using the camera) to calculate the centre point of the tool relative to the x-axis and centre of the part being cut.

In the meantime I am continuing (as quickly as the nano-lathe allows) with the line cuts. I have developed a more systematic approach in how to cut my facets and am aiming to make as many as I can with the time left on the residency. This has meant making many more facet blanks and I have started a production of facets. Jordan Haddrick from the Maker Space has been helping me with the production run. As introduced in my previous post, we have been making the facets in lots of 3, preparing them on the band saw and lathe and then moving on to the Tormach mill for the profile cutting and finishing.

Deirdre on the bandsaw cutting the aluminium lengths for the facets blanks to be cut in the Tormach mill.
Cutting the lengths of aluminium rod in preparation for batch making the facets.
Jordan drilling the central holes on the lathe. Removing the core material speeds up the cutting time on the mill.
The drilled out parts ready for cutting on the mill.
Deirdre changing a tool in the Tormach mill.
3 facets in the mill. These were removed from the stock using a hack saw and then re-faced and drilled in the mill.
Parts cut out on the mill, ready for hack sawing and facing.

 

 

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