Making engraved name badges

I’m following @jro_cambria’s lead, trying to do something similar, in my case, engraving name tags.

I’m trying to carve some ham radio name tags in these blanks:

However, I am taking a slightly different route.

I want to use the same SVG with a laser using a color key to engrave anodized aluminum blanks, and to engrave plastic on my mill. I’m using black for raster engraving and blue for vector engraving; no red because I’m not cutting. I chose a Gorton font because it is designed to engrave with an end mill, but I did tweak the kerning:

I converted the font objects to paths, imported the SVG into Kiri:Moto, and used “Merge Object Meshes”, then added a Pocket operation and selected all the faces. (Some of the letters had more than one face.) Then I chose an end mill that fits, and it traced the letters nicely.

To engrave, I plan to run it on my mill, bumping the Z on the mill down about 0.1mm at a time until I get a clean cut, since I don’t know how thick the white layer is.

Other fonts with tighter corners would need a V bit, though.

Might be a little while before I actually have the time to go carve these, but I thought I’d share how I got to a toolpath that looks sane for what I’m trying to do.

My approach may be failing.

I looked more closely at the animation, and I see that the end mill isn’t contained within the face:

KZ4LY-pocket.kmz (312.8 KB)

Turning off the Contour option in the operation seems to make it stay inside the lines.

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Yes it does! I didn’t understand what it would do. Thank you! I’m set to make some name badges!

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there is an animation bug that’s been fixed but not yet released. I’ll check if this is related.

I looked at your workspace. the contour option is for surfacing organic surfaces curved in the Z plane. by default it extends cuts to the bounds of the selection which can interfere with the part at sharp Z boundaries. so not a bug in this case. disabling contour is the right fix.

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