When building tool plugs, sometimes I find it quickest to mix manufacturing methods. In this case I CNC machined some fairly large tool plugs from MDF and bonded laser-cut letters to them afterwards. This gave sharper interior corners and saved a few machining passes across 50" x 50" parts. Wax fillets were added after bonding as well as a couple features that were epoxy cast from previous parts. These will be sent to a foundry, cast into aluminum, and become vacuum form tooling for an automotive rim pallet system (dunnage).
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