Methods involving adding a removable fixating material to a partially manufactured workpiece to stabilize a plurality of partially formed objects therein for subsequent manufacturing. In one example, a workpiece of interconnected structures is manufactured comprising precursors to the discrete objects as a function of a workpiece computer model. Manufacturing the workpiece further includes forming valleys between adjacent partially formed objects so that interconnecting portions remain to interconnect the partially formed objects. Further, the methods include removing the interconnecting portions so as to liberate the plurality of objects from one another. In some embodiments, a temporary frame is formed from the workpiece along with the plurality of objects during manufacturing.

Methods involving adding a removable fixating material to a partially manufactured workpiece to stabilize a plurality of partially formed objects therein for subsequent manufacturing. In one example, a workpiece of interconnected structures is manufactured comprising precursors to the discrete objects as a function of a workpiece computer model. Manufacturing the workpiece further includes forming valleys between adjacent partially formed objects so that interconnecting portions remain to interconnect the partially formed objects. Further, the methods include removing the interconnecting portions so as to liberate the plurality of objects from one another. In some embodiments, a temporary frame is formed from the workpiece along with the plurality of objects during manufacturing.

A method for manufacturing a metal card includes: a step for forming a metal card by laminating a stack of sheets in which are stacked a plurality of sheets, centered on a metal sheet, including adhesive sheets having the same size as the metal sheet, an upper inlay sheet having a first antenna, and a lower inlay sheet having a second antenna; a step for forming a COB accommodation space, which can accommodate a COB, by milling a certain area of the metal card using computerized numerical control (CNC) machining; a step for forming a through-hole, which exposes the first antenna and the second antenna, by milling a COB contact point region of the COB accommodation space down to the lower inlay sheet; a step for electrically connecting the first antenna and the second antenna by dispensing a conductive elastic liquid into the through-hole; and a step for bidirectionally connecting the first antenna and the second antenna to the COB by attaching the COB within the COB accommodation space so that the COB contact point is connected by the conductive elastic liquid.

The present disclosure relates to end milling methods for making microstructures, a tool comprising such microstructures, the microstructures, and replications thereof, where the microstructures are part of a structured surface configured as a security article. Some of the microstructures are configured differently from others to define an optically detectable indicia in the structured surface. Microstructures in a first group may for example differ from microstructures in a second group in terms of one or more of size, orientation, cube corner type, and dihedral angle value(s), to define the indicia or a portion thereof. The microstructures may comprise full or truncated cube corner elements, and the article may be a retroreflective sheeting.

The present disclosure relates to end milling methods for making microstructures, a tool comprising such microstructures, the microstructures, and replications thereof, where the microstructures are part of a structured surface configured as a security article. Some of the microstructures are configured differently from others to define an optically detectable indicia in the structured surface. Microstructures in a first group may for example differ from microstructures in a second group in terms of one or more of size, orientation, cube corner type, and dihedral angle value(s), to define the indicia or a portion thereof. The microstructures may comprise full or truncated cube corner elements, and the article may be a retroreflective sheeting.

In one example, an on-wing method for in-situ cutting on a wing-to-fuselage attachment includes attaching a first mount plate having a first linear bearing to provide movement in a first linear direction relative to the first mount plate, attaching a second mount plate having a second linear bearing to provide movement in a second linear direction relative to the second mount plate, attaching a tool mounting member to the second linear bearing to move with the second linear bearing, attaching a cutter to the tool mounting member to be adjustable relative to the second linear bearing, adjusting a depth position of a cut to be made on the wing-to-fuselage attachment, adjusting a width position of the cut, and moving the tool along a length direction of the cut to make the cut on the wing-to-fuselage attachment along the length direction at the adjusted depth position and the adjusted width position.

In one example, an on-wing method for in-situ cutting on a wing-to-fuselage attachment includes attaching a first mount plate having a first linear bearing to provide movement in a first linear direction relative to the first mount plate, attaching a second mount plate having a second linear bearing to provide movement in a second linear direction relative to the second mount plate, attaching a tool mounting member to the second linear bearing to move with the second linear bearing, attaching a cutter to the tool mounting member to be adjustable relative to the second linear bearing, adjusting a depth position of a cut to be made on the wing-to-fuselage attachment, adjusting a width position of the cut, and moving the tool along a length direction of the cut to make the cut on the wing-to-fuselage attachment along the length direction at the adjusted depth position and the adjusted width position.

A new technique for making cube corner elements that involves end milling is used in the fabrication of cube corner elements having non-orthogonal dihedral angles and dihedral angle errors, and arrays of such cube corner elements. A given optical face of a cube corner element may be a compound face with two constituent faces. In some cases, the constituent faces may be parallel and coplanar such that a given dihedral angle error pertains to the entire optical face, while in other cases, the two constituent faces may not be parallel, and may be associated with different dihedral angle errors.

A new technique for making cube corner elements that involves end milling is used in the fabrication of cube corner elements having non-orthogonal dihedral angles and dihedral angle errors, and arrays of such cube corner elements. A given optical face of a cube corner element may be a compound face with two constituent faces. In some cases, the constituent faces may be parallel and coplanar such that a given dihedral angle error pertains to the entire optical face, while in other cases, the two constituent faces may not be parallel, and may be associated with different dihedral angle errors.

A milling tool (10) comprises a shank section (12) and a head (14), the head being provided on a tip end side of the shank section and having cutting edges. The head (14) includes an expanding diameter section (14a) and a contracting diameter section (14b), the expanding diameter section gradually increasing in diameter as it spans toward the tip end from a base end portion adjoining the shank section (12), and the contracting diameter section gradually decreasing in diameter as it spans toward the tip end from a maximum diameter section (14c). At least one cutting edge (20, 22) is provided on each of the expanding diameter section (14a) and the contracting diameter section (14b). At least one tip-end cutting edge (32) that extends from the contracting diameter section to a center axis of the milling tool is provided on a tip end portion of the head.