I had some acrylic parts to my 3D printer that were broke when I received it in the mail so I decided to make replacements out of 6061 aluminum. The first pic is the stock piece of aluminum I got which was too thick. After shaping the pieces I routed out the same shape into a piece of 2x8 piece of wood to the same depth as the thickness of stock aluminum? then places the aluminum piece into the recess in the piece of wood as seen in the second pic. Then used my router with a half inch carbide Dato bit to mill down the thickness 1/64 inch at a time. The 3rd pic the square piece at the right shows the original thickness the aluminum stock started at compared to the finished part on the left. The black piece in the middle is the acrylic piece I copied from to make the part. The last 2 pics show the finished pieces.
