I selected the diamond shaped vectors first and then used the bevel tool at about 11 degrees with a .3" vertical edge to create the reliefs. I knew they couldn't be taller than 0.8" I added a subtle texture using a bitmap from my Texture Magic collection called 'SPLOTCHES 1' this was created to a depth of 0.1"
The next step was the ring with the degree notches around the perimeter. Its a simple flat 1" thick relief. Then I selected this and the little box vectors and subtracted the notches by creating a negative relief. O then created an offset vector around all the pieces and merged them. This was made into a o.0" thickness relief. Then I selected all of the reliefs and merged highest. I tool-pathed the file using a 3/8" ball nose bit with a 90% overlap. It was machined in a single pass.
Since this sign would be two sided I needed to build each side and then flip it to make the other side. Because I built the files somewhat in a freehand way I couldn't simply route two copies and then expect them to fit together.
Next up was the ring with the name of the business. This was done by creating a simple domed file, then adding the same splotches bitmap for the textures. The writing and stars were beveled at 21 degrees with a 1.5" shoulder. Since this was perfectly round I could route two identical copies - one for each side. The tool-pathing was done in two passes. A rough pass was done with a 0.1" offset with a 3/8" ball nose bit at a 50% overlap. Then a single final pass was done with a 1/8" ball nose with a 80% overlap.
All four pieces were to be routed from 1" thick 30 lb Precision Board. Next entry I'll be showing how we assembled the pieces...
-dan
