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Mass Prodution of Poker Chip Trays

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Forum topic by hdgis1 posted 247 days ago 919 views 0 times favorited 12 replies Add to Favorites Watch
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hdgis1

6 posts in 849 days


247 days ago

I dont normally make this many of anything but got a commision that requires me to make 144 poker chip trays. Drilling out 12 or 14 trays is no big beal but I have no plans to drill 144 (720 holes). Lets hear some ideas on how you guys would approach this.

Chris


12 replies so far

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Sanding2day

918 posts in 431 days


#1 posted 247 days ago

Am curious what incredible solution exists but good news as I see it the pieces can be made two at a time and split on the bs, so only 360 holes to drill :)

-- Dan

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chrisstef

10244 posts in 1590 days


#2 posted 247 days ago

Some one with a line boring machine might do the trick if they can use a bit that large on the machine.

Stack em up 2 high and you’re down to 180 holes.

-- "there aren’t many hand tools as awe-inspiring as the #8 jointer. I mean, it just reeks of cast iron heft and hubris" - Smitty

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bigblockyeti

1288 posts in 305 days


#3 posted 247 days ago

First off I would try to use the longest piece of lumber I could to start with, so that individual trays could be cross cut off the blank. Second I would remove as much wood as possible first on the tablesaw, two cuts at 45 degrees per half cylinder for a total of ten cuts. Third I would look into a bit (probably expensive) that would remove the remaining wood and form the half cylinder the chips sit in. If it were a bit for the router, it would need to be a high horsepower variable speed router, a shaper would be better suited given the requirements of such a bit. Do you anticipate having to make any more in the future? If so the undoubtedly high cost of such a cutter/bit might be easier to justify.

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casual1carpenter

353 posts in 1060 days


#4 posted 247 days ago

well you beat me to it, lol. was looking up a bit, the Freud 18-130 Round Nose Router Bit 1-1/4 or similar might do you if you remove material first as stated above. bevels or dado to remove bulk of material.

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NiteWalker

2632 posts in 1161 days


#5 posted 247 days ago

A good forstner bit with the dp fence set and those holes will go super quick. I highly recommend colt maxicut bits. They cut incredibly fast and clean.

-- He who dies with the most tools... dies with the emptiest wallet.

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hdgis1

6 posts in 849 days


#6 posted 247 days ago

Oops! 360 holes is correct. Math….pffft.

I used the maxicut bits and the do drill well. However, there is an unacceptable amount of tear out that occurs.

I’m really looking for a shaper quality cut that requires minimal sanding.

Chris

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a1Jim

111999 posts in 2161 days


#7 posted 247 days ago

With that many I would look for someone with a CNC set up.

-- http://artisticwoodstudio.com Custom furniture

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PRGDesigns

203 posts in 897 days


#8 posted 247 days ago

+1 on the CNC.

-- They call me Mr. Silly

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stevejoly

3 posts in 642 days


#9 posted 245 days ago

What about a router? Make long trays with 5 channels with a cove bit or large round nose bit . Then cross cut the individual trays to length.

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Loren

7154 posts in 2232 days


#10 posted 245 days ago

If you did not make the samples, they were perhaps done
on a planer/moulder with custom knives in multiple passes.

Considering sanding and tearout issues, I would entertain
having the coves milled on a cnc machine and sanding
with blocks. Drilling seems goofy, but I’ve never drilled
to achieve a finished profile like that so I can’t say it’s
unfeasible.

-- http://lawoodworking.com

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JAAune

734 posts in 901 days


#11 posted 245 days ago

I think a1Jim is on the right track. That sort of work is perfect for CNC. Someone with an industrial machine might charge as much as $250 per hour but they’d have everything done in an hour. You’d probably pay no more than a couple dollars per unit.

I don’t know how wide they are but it would be ideal to mill out long blanks on the CNC then crosscut to length after sanding.

It’s either that or some sort of shaper or molder setup but custom knife grinding fees would probably cost more than CNC milling.

-- See my work at http://remmertstudios.com and http://altaredesign.com

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tefinn

1197 posts in 1021 days


#12 posted 245 days ago

One of our fellow LJs builds poker chip boxes. Jimboe posted his jig for making the coves for the trays. Maybe you can use a set up like his.

-- Tom Finnigan - Measures? We don't need no stinking measures! - Hmm, maybe thats why my project pieces don't fit.

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