We recently cut a box using our EasyRoute CNC Router bit, but this time we’re going to try something different.
We’re changing to a new router bit from our Tooling Range and seeing if we can get a cleaner fold and, most importantly, a stronger box.
So, why did we decide to change the bit?
Let’s take a closer look.
With the first router bit, we had to cut fairly deep into the aluminium to get the material to fold nicely. It did the job, but there was a problem.
The deeper we cut, the less aluminium we had left at the fold. That made the corner quite thin and brittle.
For a small box, that might not be a huge issue. But when you’re making bigger boxes, cabinets or frames, you really want to keep as much material as possible.
Otherwise, the fold can become a weak point.
And that’s exactly what happened here. When we started folding the first piece, it was so brittle that it actually began breaking apart.
Not ideal.
Trying the New Router Bit
So, we changed over to the new bit and ran the cut again.
Straight away, you can see a difference.
The new bit still cuts slightly into the aluminium, but it leaves more material behind. That’s exactly what we want.
Aluminium is also quite soft, so you can get a little bit of compression where the router bit passes through the material. When the aluminium is thin enough, it can even stretch slightly.
Once we took the piece off the machine, the difference was much clearer.
Instead of having a sharp, fragile corner, we now had a nice radius along the fold.
That gives us a much stronger corner.
Why the Radius Matters
The rounded edge might not seem like a big deal, but it makes a difference when you’re working with larger pieces.
A sharp, deep cut leaves very little material at the fold. A more rounded cut keeps more aluminium in place, giving the corner some extra strength.
We can also use a 91-degree router bit for this type of application.
One of the advantages is that it leaves a small amount of space in the groove, which gives us room to add adhesive when the box is folded.
So we’re not relying only on the aluminium to hold everything together. We can also add adhesive to strengthen the joint.
The Results
When you compare the two cuts, the difference is pretty clear.
The old piece was so brittle that it started breaking when we tried to fold it.
The new piece is much more solid. We’ve got more aluminium left behind, a cleaner radius and enough space to add adhesive.
The result is a much stronger box.
And that’s really the important lesson here.
The AM8C router had no problem cutting through the aluminium. The machine can handle the material without a problem.
But choosing the right router bit is just as important as having the right machine.
Sometimes you don’t need to cut deeper. You just need to find the right balance between getting a clean fold and leaving enough material behind to keep everything strong.
We tried two different router bits on essentially the same job, and the difference was impressive.
Now we’ve got a stronger and better-looking box, and we’re ready to move on to the next project.
In the next video, we’re going to have some fun with the AM8C router and cut some gears.
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