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How do I create a cutout for a display window?

To do this, start by creating a rectangular cutout with your desired dimensions and location for the display window. Next, create a “rectangle in a rectangle” cavity around the cutout. We suggest allowing the edges of the cutout and the cavity to overlap slightly to ensure against any unattractive burring. This process will create an object that forms a rectangle cavity around a rectangular cutout.

 

 

 

More details are available in the demo file: cut-out.fpd

More details are available in the demo file: acrylic-display.fpd

 

How can corners be milled off cleanly, with no radii?

There are different ways to go about this. First of all, radii for each corner of the panel can be input in the Front Panel Properties dialogue box. Secondly, it is possible to position a rectangular hole, or other objects, directly over the corner. In order to keep the corners sharp-edged, the objects should overlap the corners, as demonstrated below. 

 

 

 

Is it possible to apply a beveled edge on a panel?

Yes. A 45 degree bevel can be applied to any panels' outer edge or interior cutouts. To order bevels, leave a note in the “Remarks” box in Panel Properties, making sure to specify the desired depth of the bevel. We will confirm additional charges before processing your order.

 

Do you offer metal bending?

 No, we do not. We will, however, customize an already bent panel or enclosure. 

 

If I send you a drawing, will you design it in Front Panel Designer for me?

Yes! We charge $80 an hour for this service, due at time of ordering. Send us your CAD program file or your dimensioned drawing and we will convert them into manufacturable .fpd files.

Please provide the following files and information if sending us your drawings:

• Recommend CAD program files: .dxf and .dwg

• Please specify the material, thickness and dimensions not only for different front panel features, but also where required for engravings.

• Engineer contact information

  
  

I have a file in .XYZ format, can you manufacture my panel using that?

No, we can not. However, we do offer design services to convert a design from .XYZ to .fpd. See the question above. 

 

What format does my company logo need to be in order to have it engraved on my panel?

Logos can be engraved into your panel using HPGL files. HPGL files can be created using a vector illustration program, such as Corel Draw or Adobe Illustrator.

 

Will you convert my logo to an HPGL file for me?

Yes, we will convert your logo to an HPGL file. Most .dxf and .cad files cost $30 to convert to HPGL format. However, more complex files and all pixel based formats, such as .jpg, are $180.

 

Do you have enclosures?

Yes, we offer two types of extrusion systems for creating enclosures, side profiles and housing profiles.

Side profiles form two complete sides of the enclosure, and include grooves for inserting boards. The height of the enclosure is fixed, while the depth and width can be customized to your design.

Housing profiles, on the other hand, form four edges of the enclosure. Thus, all three dimensions can be customized.

A detailed description on how to design an enclosure can be found here.

 

What are the dimensions of the housing / side profiles?

Dimensions and drawings of all available profiles can be found here.

 

Can excess material (cutouts) created from milling be returned to me with my panel?

Yes, we can return the cutout portion upon request. Please make a notation to this effect in the “Comments for Production” field in Front Panel Properties. Also, when considering the size of the cutout, remember to consider the plunge path of the milling cutter with a width of approximately 10 mm (see drawing below). In other words, the cutouts are not suitable as drive shutters, for example.

 

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Is it possible to manufacture brass front panels?

Yes, we can manufacture front panels on brass material provided by our customers. We do not, however, stock brass material. Please keep in mind, when milling on brass material, the surface is softer than that of anodized aluminum. It is, therefore, possible that scratches may occur during manufacturing. Likewise, brass alloys vary and this can impact the sharpness of engraved objects on brass material. Additional charges may apply. 

 

What other customer provided material can be used?

We are able to work with most non-ferrous materials, including a variety of aluminum, brass, copper, plastics, etc. We can also work with powder-coated and painted material, and machine bent enclosure parts. If you are unsure about your material, please feel free to contact our customer service team.

 

Why not steel?

Our machines are optimized for processing aluminum, and other non-ferrous materials. Our high performance spindles can not absorb the cutting force required for steel.

 

Can I send you a pre-fabricated panel for further customization?

Of course! Please select the option “Use customer provided material” in Front Panel Properties in the relevant .fpd file. The correct price will then be calculated.

 

What about metal with flanges on the back?

Yes, we also accept metal with flanges on the back.

 

Will you powder-coat my customer provided material?

Unfortunately, we are unable to provide this service at this time. 

 

Where do I send my material?

Our physical address is:

Front Panel Express LLC
5959 Corson Avenue S Suite I
Seattle WA 98108

Please provide your reference number with your material when sending to us.

For further information, please see our newsletters on Customer Provided Material and Milling on Panels You Provide.

 

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Is it possible to have free outside contours?

Yes, free outside contours can be created by inserting objects, such as curved slots and rectangular holes, along the edge of the panel. With this method, if the size of the objects along the edge of the panel significantly increase the milling area, we must manually adjust the file, which will increase the cost an average of $15-$45.

However, the simplest and most cost effective way to create free contours, both inside and out, is through a .dxf file import. A .dxf file can be created using some CAD programs, as well as graphics software, such as Corel Draw and Adobe Illustrator. We will also create a .dxf file for you, for which the fee varies.

 

How are complex interior contours for cutouts created?

Using the same process as for free outside contours. DXF file imports can be used for cutouts and cavities. Again, these can be created using some CAD programs, and graphics software such as Corel Draw and Adobe Illustrator.

 

How do I insert standard holes for a 19" rack panel?

Holes for standard 19” rack panels can be inserted in Front Panel Designer using the “Insert System Holes” menu item.

 

How do I reset the point of origin?

The point of origin, or zero point, is marked on a front panel with a blue cross. In order to move this point, select the option “Set Origin” in the “View” menu, or press the “N” key. There are several ways to move the origin:

• Click the mouse in the location that you would like to move the point of origin to

• Insert exact coordinates by pressing “M” to bring up the “Move” menu

• Using the numeric 10-key pad, imagine the key pad as coordinates within your panel. By pressing 1, 3, 7 or 9, the point of origin will be placed in the corresponding corner. 2, 4, 6 and 8 will move the point of origin to the midpoint of the corresponding edge, while 5 will move it to the center of the panel.

  
  

How do I create a round scale?

There are two ways of creating scales:

• Create it in another program, e.g. Corel Draw or Scale Generator, and import it into Front Panel Designer as an HPGL file. This method has the advantage that you can use the manifold possibilities of the graphic program.

• With Front Panel Designer: First of all, set one axis of your scale. For ease, we suggest a line that is either horizontal or vertical. You can then add your lettering. Experience has shown that the lettering should be centered. Now mark both objects with the mouse and press the right mouse button, click on “move / rotate” and under “Action”, select the option “Rotate”. Directly under this, select the option “Apply action to copy”. You can enter the center of rotation under absolute x, y (ie the position of a thru-hole with a rotary switch) and the angle of rotation on the bottom right of the menu. The scale can now be completed by using the function “Repeat” in the “Process” menu.

  Using this method, the lettering will be slanted. This can be adjusted by marking the lettering, pressing the right mouse button and setting the angle of rotation to 0 degrees under “Properties”. You can then also change the lettering (numerical values, etc).

How do I create a macro element?

A macro element is a grouping of standard objects that you regularly place on your front panels. In order to create a macro element, you will first need to align your standard objects on a front panel. Then, mark all of the objects and turn them into a group by selecting “Group” in the “Selection” menu. When you process the properties of this group, you can fix the reference point of the group. For example, you can adopt the reference point of one object from the group. This can simplify placing the macro element in the future. With the group of objects marked, select “Create macro element” from the “Selection” menu. A dialogue box opens, in which you can enter a file name, and a name for the macro element.

 

Will you mill on the back side of a front panel?

Yes, we will. Cavities, countersinks and blind holes can all be placed on the reverse side of a panel. To do so, simply check the “Place on reverse side” box when creating each object. The object(s) will then be represented with cross-hatching on the panel design.

 

How do I put text or other objects on the back side of a panel?

For panels that require features other than cavities, countersinks and blind holes, you will need to create two separate design files...one for the front of the panel, and another for the back. You will need to notate in Panel Properties that these two files are for the front and back of one panel. 

More information on placing objects on the back of your panel can be found on our Forum.

 

How can I incorporate other fonts into my panel design?

If there are other fonts you would like to use on your panel that are not available in Front Panel Designer, you can create an HPGL using such fonts in a program like Corel Draw or Adobe Illustrator. Then, import the HPGL file into Front Panel Designer and we will then engrave your font as a logo.

 

How do I add special characters, such as the CE symbol?

You can find a character map, with instructions on how to insert special characters here. Since special characters vary between fonts, there is a separate file for each of our 23 fonts. 

 

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I am using an old version of Front Panel Designer, will the pricing still be accurate?

Pricing is only guaranteed to be accurate when using the latest version of the software. Currently, the most recent version is Front Panel Designer 4.1.1. If you are using an older version, your price may be adjusted to reflect current pricing.

 

Can I pick up my order?

Yes, simply select “Self Collection” at checkout. You will be informed by phone when your order is complete and ready for pickup. Completed orders are available for pickup Monday through Friday, 8:00am – 5:00pm. Payment may be made in advance, or when picking up your order.

We are located at 5959 Corson Avenue S Suite I, in Seattle Washington 98108.

 

Will you ship my panel via USPS?

Yes. Our preferred method of shipment is UPS. But, we realize that this is not always available or convenient, and are willing to work with your shipment method of choice.

 

What other options do I have for delivery?

We will ship your order via UPS, FedEx, or USPS. For those in the Seattle, Washington area, we also offer a courier service.