Thread: Hair Thin Cuts in a Metal Comb

Hello there!

I have a future project of making a music box!

Since it's not easy to buy a good metal comb, I want to make a metal comb of my own.

There is a picture of a really small comb used in a cheap music box mechanism from China.

WhatsApp Image 2020-07-11 at 22.25.26.jpg

The dimensions are: 24mm x 16mm x 1.5mm [0,94 x 0,62 x 0,05] inches(really small)

1) My question to you all is, how in the hell they made all those 17 hair thin cuts in that small plate metal??

2) Whats would it be a viable way to make a metal comb? Even if it was bigger than the one in the pic.

I tried to make a metal comb with corel then sending to a place that makes metal laser cuts, but it was not possible because it was so small that the fins was gonna melt(at least that they told me that)

Thank you very much!

The fins will not melt, they didn’t want the job. Most CNC cutting places are not interested in DIY projects as they aren’t economically viable.

You could cut the slots in that with a cutting disc in the end of a Dremel tool and a steady hand. If you don’t have a steady hand you could rig a guide fairly easily with a couple of pieces of timber.

Originally Posted by racingtadpole

The fins will not melt, they didn’t want the job. Most CNC cutting places are not interested in DIY projects as they aren’t economically viable.

You could cut the slots in that with a cutting disc in the end of a Dremel tool and a steady hand. If you don’t have a steady hand you could rig a guide fairly easily with a couple of pieces of timber.

Thank you for your answer!

Before sending the file, I already thoght of that problem and made a A4 size file full of combs to make more viable for them.
When they replied to me, they told me that "cutting in carbon steel [1020] 0.5mm thick has no way to do it because the laser will melt the fine parts of the comb, this type of cut we recommend making in stainless steel"
After that, I asked them to cut in a carbon steel with a 1.5mm thick and they told me that "the greater the thickness, the greater the distance that must have between the cut lines". After that, I replied again and got no answer anymore.
I wonder if I made a bigger size file like a A3 or A2 to make them more intersted or just search for another place( Although there are not many CNC cutting places in my town...)

I like the Dremel idea but I need precision. If you or anyone else could give me more ideas or ways of doing this kind of cut I would really appreciate it!
I found a video on youtube on how a music box is made, at 0:55 they briefly explain how the comb is made using a circular saw with some oil that appears to make perfect cuts in the plate.

https://www.youtube.com/watch?v=RXf924CGLbs

Thanks again!

Originally Posted by racingtadpole

The fins will not melt, they didn’t want the job. Most CNC cutting places are not interested in DIY projects as they aren’t economically viable.

You could cut the slots in that with a cutting disc in the end of a Dremel tool and a steady hand. If you don’t have a steady hand you could rig a guide fairly easily with a couple of pieces of timber.

Thank you for your answer!

Before sending the file, I already thoght of that problem and made a A4 size file full of combs to make more viable for them.
When they replied to me, they told me that "cutting in carbon steel [1020] 0.5mm thick has no way to do it because the laser will melt the fine parts of the comb, this type of cut we recommend making in stainless steel"
After that, I asked them to cut in a carbon steel with a 1.5mm thick and they told me that "the greater the thickness, the greater the distance that must have between the cut lines". After that, I replied again and got no answer anymore.
I wonder if I made a bigger size file like a A3 or A2 to make them more intersted or just search for another place( Although there are not many CNC cutting places in my town...)

I like the Dremel idea but I need precision. If you or anyone else could give me more ideas or ways of doing this kind of cut I would really appreciate it!
I found a video on youtube on how a music box is made, at 0:55 they briefly explain how the comb is made using a circular saw with some oil that appears to make perfect cuts in the plate.

https://www.youtube.com/watch?v=RXf924CGLbs

Thanks again!

17 cuts with 1mm thick cutting disc would leave nothing left, the part is only 16mm wide.

Thank you for your answer!

Before sending the file, I already thoght of that problem and made a A4 size file full of combs to make more viable for them.
When they replied to me, they told me that "cutting in carbon steel [1020] 0.5mm thick has no way to do it because the laser will melt the fine parts of the comb, this type of cut we recommend making in stainless steel"
After that, I asked them to cut in a carbon steel with a 1.5mm thick and they told me that "the greater the thickness, the greater the distance that must have between the cut lines". After that, I replied again and got no answer anymore.
I wonder if I made a bigger size file like a A3 or A2 to make them more intersted or just search for another place( Although there are not many CNC cutting places in my town...)

I like the Dremel idea but I need precision. If you or anyone else could give me more ideas or ways of doing this kind of cut I would really appreciate it!
I found a video on youtube on how a music box is made, at 0:55 they briefly explain how the comb is made using a circular saw with some oil that appears to make perfect cuts in the plate.

https://www.youtube.com/watch?v=RXf924CGLbs

Thanks again!

Jewellers coping saw blades can be had down to 0.2mm maybe finer.
Rig the material between two stiffening parts (wood, plastic, or similar) and get'er done.

I'm interested to, as I have an old music box I want to restore.

Given it seems so difficult, I wonder how the originals were made.
Looks like slitting saws are available at 0.2mm. I wonder if that would work.

Hi Commander, Guys,

Originally Posted by Commander_Keen

Jewellers coping saw blades can be had down to 0.2mm maybe finer.
Rig the material between two stiffening parts (wood, plastic, or similar) and get'er done.

That is how the Swiss music box makers did it long before power tools. Scribe lines where you want the cuts and follow the lines. I actually have some jewellers saw blades that I bought a couple of years ago from a firm in Australia. I made a frame for them, actually very easy to use as long as you keep the blade taught and don't try to rush the cutting. They are very brittle and will break if you do.

Anyone for EDM

Water jet cutter.

Waterjet has about a 1mm wide cut, so no good there. EDM would be the go if you know someone who has one

Originally Posted by frnnd

There is a picture of a really small comb used in a cheap music box mechanism from China.

WhatsApp Image 2020-07-11 at 22.25.26.jpg

1) My question to you all is, how in the hell they made all those 17 hair thin cuts in that small plate metal??

Flog a Chinese kid hard enough and he can achieve anything

Thank you for your answer!

Before sending the file, I already thoght of that problem and made a A4 size file full of combs to make more viable for them.
When they replied to me, they told me that "cutting in carbon steel [1020] 0.5mm thick has no way to do it because the laser will melt the fine parts of the comb, this type of cut we recommend making in stainless steel"

After that, I asked them to cut in a carbon steel with a 1.5mm thick and they told me that "the greater the thickness, the greater the distance that must have between the cut lines". After that, I replied again and got no answer anymore.
I wonder if I made a bigger size file like a A3 or A2 to make them more intersted or just search for another place( Although there are not many CNC cutting places in my town...)

I like the Dremel idea but I need precision. If you or anyone else could give me more ideas or ways of doing this kind of cut I would really appreciate it!
I found a video on youtube on how a music box is made, at 0:55 they briefly explain how the comb is made using a circular saw with some oil that appears to make perfect cuts in the plate.


Thanks again!