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3D Printing

4 Axis CNC

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Our BfB300+ dual extruder 3D printer gives incredible advantage over common plastic machining (subtractive) prototyping methods. A myriad of colors are available from 3mm ABS, PLA, Nylon, and plasticized wood. We have produced parts including electrical wiring fixturing, R/C control transmitter antenna and FPV monitor case modifications, and functional flying MAV external and internal parts.
Our 4 axis CNC machine provides excellent subtractive prototyping opportunities in most metals, carbon fiber and fiberglas, plastics, and wood. An extensive collection of mills and other tools from 0.005" to 3/4" allows for machining of very disparate sized features. Our machine has a work volume of 14"x7.5"x13.25", tapping head, full flood cooling, and a 4th axis tailstock.
Our PCB router has a 10"x13" working area for single and double sided PCBs of 1/32" and thicker. Machine accuracy and repeatibility allow for very small SMT parts/pads as well as through hole components. Circuits designed and laid out in Eagle are transferred to IsoPro software and the PCBs spun individually or panelized, giving PCB layout turns of hours or even less.
One of the newest additions to our shop is a full size vacuum molding machine capable of handling ABS and acrylic sheets up to 12"x18". Coupled with the additive or subtractive machines described above, detailed vacuum parts are available with turns measured in hours.
Smaller (1.25 in^3, 1oz. mass) volume ABS (and other engineering plastics) injection molding has recently been added. This capability allows very finely detailed parts that can be glued or bonded to 3D printed or CNC machined assemblies. Injection molds can either be CNC machined or mirrors 3D printed and then cast in high temperature resin.
Moderate sized (64 in^3) non ferrous (lead, tin, brass, aluminum, some alloys thereof) metal casting is also planned for 2Q 2013. This capability will effectively allow the production of 5 axis CNC parts, as the casting procedure will allow complex geometries to be formed, after which 4 axis CNC completes the part.
AetherMachines bench test capabilities include over 14 channels of DSO and analog oscilloscope, 10+ channels of DC power, 4 AWG/function generator channels, 4+ DMM channels, 16+ channels of logic analyzer including SPI, I2C, CAN, 3+ TC channels, an IR camera, 2 tach channels, anemometer, RF spectum analyzer, 300W DC load, 15kV high wattage source, two video borescopes, megapixel cameras, and digital and conventional microscopes.
AetherMachines assembles its prototypes using speciaty adhesives, socket head and Phillips hardware, retaining clips, and press fits. Wiring harness and connector assembly achieves robustness without sacrificing manipulability or further development. Assembly steps, torques, and overall protype manuals provide the user with excellent ability to understand prototype features.
Low volume production of PCBs and 3D printed and machined metal and plastic parts are also available. Production includes agreed on unit test and documentation of CTQ values.