Ask HN: Can you make me a 50 meter scroll saw blade?
I'm hoping for both a) direct responses if you can make this (ideally with price tag!) and b) meta responses on where else to look, how else to look, how anybody finds others willing to take on projects that are slightly "out there", etc.
These blades exist on today's market as size "2/0 scroll saw blade" (google-able) and are about 5 inches. I've been looking for the past several months to create the same thing, but with teeth for a continuous 50 meter length. I would use these blades in a manner like a bandsaw, but without being in a closed loop. I previously worked on a "CNC scrollsaw" (google-able) and this new blade would power that machine's successor.
I've brainstormed and refined many ideas on in-house (DIY) manufacturing, outsourcing, and some combination.
So far, I've tried contacting:
* The 3 well known manufacturers of these blades: 1 got a prototype to me before saying no (the prototype had teeth, then gap with no teeth, then teeth, etc). 1 said no. 1 had no response
* A reseller of these blades who then asked one of the same manufacturers, but got the same response
* Umpteen companies on Alibaba, few leads, no winners
* Multiple manufacturers that do punch & die work, varying levels of no or no response
* A manufacturer that does reel to reel etching, still in discussion, but seems unlikely
* Multiple manufacturers that do custom CBN form wheels for grinders. skeptical responses and I would need a good spindle to run them
* A manufacturer that makes a fairly similar product to what I'm looking for, just in slightly larger size, but they said no
* A discord of machinists, who had some helpful tips, but no leads
* Steel suppliers for the raw material (flat wire/ribbon is likely the best), but obtaining small (ie < 1 ton) amounts has not been fruitful
I think the DIY approach is not impossible for someone with more skills and better space+equipment than me. A 50m length has about 25,000 teeth, so whatever process it is (milling, punching, grinding, <something else>), it needs to be repeatable. The best idea I've had is a purpose built CNC grinder with computer vision for wear compensation and alignment, but a major hurdle with grinding is the corner radius would ideally be <150 um (300 um tooth height, so that leaves half the height as flat). I could ramble about more specifics, but maybe that gives a bit of flavor and intrigue if someone is interested in working on this.
Thanks!