I went to my local acrylic monger yesterday and was captivated by this huge block of gray UHMW.  It was _begging_ to become an SFS box.

The block was about 10 inches long, 8 inches wide and 2.5 inches thick.  I needed to pare it down to 1.75″ thick first…

You can see the UHMW chips flying away from the cutter.  I’m using a .50″ downshear cutter running at 12,000 RPM with a feed rate of 1.7in/sec.  That cutter is an _animal_ in this stuff.  I’ve never cut UHMW before and it was definately an experience I won’t soon forget.  I’ll be cleaning up little bits of gray plastic swarf for the rest of my life I think.

Now we get on to the interior of the SFS box…

All during the cutting process, I was trying to suck up as much of the swarf as I could with a narrow shop-vac hose.  The best I could do is keep the stuff from clogging the cutter…

All done!  What a f*cking mess. *sigh*  The block of material has been glued down to a sheet of scrap plywood with 3M 77 spray adhesive.  Worked great!

Here’s the end results:

I really don’t care for the finish the cutter left on the box so this will likely be just a fun paper weight.  Tomorrow I’ll get the .062″ aluminum cover plates made…


  1. Bre on 02.01.2010

    Very cool!!!

  2. Eric LeClair on 06.28.2016

    Awesome. Love to see an update on this. I would also suggest using 3d printing with ‘Tough Resin’ by Formlabs. Great for real strong prints / home projects. http://formlabs.com/products/materials/tough/

  3. admin on 06.29.2016

    If it wasn’t nearly 3x the cost of the MakerJuice resin I have now, I might look into it. 🙂

    If you rummage around the posts here, you’ll see how the SFS box ended up.

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