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Making a Smile Sign Out of Polycarbonate

Total Time 3 hrs.      Date: 02-03-04

Someone threw this beautiful piece of polycarbonate in the trash at work!

What, wasted material! I quickly grabbed it and put it in my pocket. After having it for months I finally thought of something to do with it; my brother's practice logo! I cut a piece of wood at the angle of the piece (about 19 degrees) and mounted it via, what else, Double Side Scotch tape.

The wooden piece was also mounted to the mill via the tape. A reground carbide endmill (1.20mm) was used and the logo was traced out using Rhino3D. The part that took the longest was tracing out his logo in Rhino and making sure it was right.