philrider7 wrote:As an industrial designer, I design products and as disc golf nuts, I wish I could do my own disc ( the only thing missing is the cash to do the machined mold! I guess China might come to help there)...Also, I work with a special technical plasctic often called UHMW for Ultra-high-molecular-weight polyethylene and I always wonder if we could use the ultra resistant plastic as it can resist abrasion (its self lubricate), resist high and low temps and can be formed like Vibram disc (compression molding).
Sounds interesting, what does it feel like? Tacky? Is it significantly more dense?
philrider7 wrote:Side note on the last video about Vibram manufacturing process, it's compression molding compare to injection molding.
PMantle wrote:Ah, forged vs. cast
Or maybe cut? I could also imagine a process of cutting a disc from a chunk of plastic with the right kind of initial geometry to avoid shrinkage artifacts and asymmetric residual stresses. Perhaps it could even be annealed somehow? That would probably be the most reliable and consistent method, although it might be a tad more expensive and time intensive.
For example, think about molding a lens-shape axi-symmetric chunk of plastic with mirror symmetry about the mid-plane, and set it aside for gradual cooling while still at elevated temperatures. The symmetry would translate into symmetric shrinkage after cooling out of the mold, reducing artifacts. Then cut a cylindrical chunk out of one side, to leave a flight plate and rim, and finish it with precision cutting tools to shape the nose. Et voila.