Modelling Embossing Roller

[frankiebailey99]

Would like to know the best way of modelling one of these. I have the Image2Surface add in installed and that lets me convert a grayscale image into a surface, next I need to know the best way to give it a body and then wrap around a cylinder. Would the easiest way to do it be to convert to sheet metal and then somehow cut the pattern into it and fold  it? This will be manufactured on a 4th axis CNC. Thanks! 

https://www.thingiverse.com/thing:4257414

[TrippyLighting]

Image2surface will create a interpolate "smooth" T-Spline heightmap with the heights responding to the grey levels in the image.

If you want shp transitions, a black-and-white image and an image-to-.svg tracer (for example, the one in Inkscape) will work better.

However, be advised that there can be many stumbling blocks in that workflow. often .svg images do not adhere to the precision needed for a CAD application. This is definitely not a beginner project.

[Warmingup1953]

This file is already a "Roller" Is it this pattern you wish to emulate or something else? Do you have it as a flat image or vector?

[TrippyLighting]

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Do you have it as a flat image or vector?

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He described a gray scale image, so it must be a raster graphics image.

[frankiebailey99]

Hi  yes this is the style of pattern id like to emulate using custom depth maps my friend will make for me like the ones used for relief wood carving example below. What would be the most efficient workflow for this as it takes a lot of computing power, would there be a way to make it compute faster at a lower quality?

I am getting close using sheet metal rule unfolding a cylinder  then cutting into the flat with the image then refolding it but getting a lot of errors on the way.

https://a360.co/3PZEk6W

[frankiebailey99]

Yes, and I know this isnt a beginner project as I still have to figure out the cam side of things but Its definately possible, for reference Im trying to create custom rollers for leather belt embossing like the ones linked below, I have been 3d printing them so far but can only get so much detail, 4th axis CNC would definitely be the best option I think.

https://www.etsy.com/nz/shop/LeatherStampsTools?ref=profile_header&section_id=27066169

[TrippyLighting]

I followed the link and looked at the patterns of those stamps.

They have very different characteristics from the Thingyverse roller.

If you can enable download, then I can also take a look at your design 😉

[frankiebailey99]

Ive figured out its easier to use blender to turn the design into mesh then import to fusion, its having some trouble turning into a solid though haha and cant wait for the CAM side of the headache. Its not letting me enable the downloads but I can send you a file when I go back to work as they have the full version. The embossing rollers on leather stamp tools are similar to the model i sent in the fact that its a cylinder with an image/complex texture wrapped to it. For instance I would like to make one with chess pieces going around it.

[HughesTooling]

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@frankiebailey99 wrote:

Ive figured out its easier to use blender to turn the design into mesh then import to fusion, its having some trouble turning into a solid though haha and cant wait for the CAM side of the headache.

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You can machine directly from a mesh as long as you position it correctly. You might want to add a cylinder (the cylinder and mesh don't need to be joined) in Fusion to help with the setup.