[sdiy] alternatives to Schaefer front panels for Canadians? Good software to use?

[Modcan Synthesizers]

As a Canadian maker of synth panels, here is what I do.

For my B series panels:

I make up an accurate drawing for the holes and panel shape and send 
it to a sheet metal shop that has a laser that cuts aluminum.
Costs about $15-20 per panel

www.emachineshop.com  would be a good place to start for one-offs

They cut them out and I pick it up and take it to another shop and 
they paint it with baking enamel.
Cost about $2.50 per panel in lots of 200

Most paint shops will do a couple of parts but you might have to go 
for a paint they have in stock.
The paint I use costs about $150 a gallon and you have to buy the whole gallon.

I then do another drawing with graphics and text etc and send the 
file to a local silk screen making shop.
They convert the file to film and burn a screen. I use a 24x24 
aluminum frame screen so can get about 4-6 designs on one screen.
screen cost and film about $150 but it will last for years.

Then I get some epoxy ink that won't dry unless you heat it up to 350C

Make a jig to hold the panel and get the squeegee out.
Takes about 30 min to screen 10 panels.
Stick them in my large toaster oven and cure the epoxy for 10 minutes
and they are done.

Now for one-off I would skip the silk screen and send artwork to a 
company that can make a dry transfer.
Chromatek is what we used to call it in the model making biz.
It is like letraset. Like what these guys do http://www.allout-graphics.com/

And then I would put a coat of clear enamel or something over top to 
protect it.
This should yield a very professional looking panel with reasonable durability.

Bruce



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