Quote:
Originally posted by Cathar
Fly-cut both sides.
Then machine it.
Then lap it after it's machine.
The heat and stresses of the machining will cause the copper to bend slightly (in the order of a small number of microns), but enough to require lapping again after machining.
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Thats the way I would do it to. That way the peice can sit flat in the vise or on the table and your depths will be consistant on the design.
MadDogMe was pretty close except for the last part. The metal will distort again if the design being milled into it causes heat build up. The parts that are thinner will warp a little tweaking the whole peice, but not much. When copper, or any metal really, is roled into a flat bar it is always concaved in the middle more so than the outer sides and if it was in a sheet form then it is going to have all kinds of humps and drops in it. Just the way it is made. Google for metal manufacturing and you should be able to see why.