The very first metal piece I cut when I got my Workbee CNC mill was a Batarang replica from the Dark Knight … including a few cuts in places where do not belong, it was a learning experience. I keep this Batarang in office at work mostly as a conversation starter.

A few days ago one of my colleagues, who is a big Batman fan, asked me if I could make him one as well. My chance to check if I learned anything about milling Aluminum over the last few month.

The design is a DXF file I found on 3axis.co , the stock is a 2,5mm thick piece of some unknown Aluminum alloy I found in my fathers workshop.

The material was not very flat, I tried to my best to flatten is out but in the end I decided to fix it to wasterboard using double sided sticky tape and a layer of XPS foam in between to compensate for the bends. By the way I am not using any kind of cooling which is the reason for the low feed rate, anything faster will start melting in alloy and gum up the bit.