I am testing a possible flute making material made locally in Tacoma called Richlite. Its density at 78 pounds per cubic foot is very close to Blackwood and identical to Mopane. It comes in sheets of a minimum size of 4 X 8 feet, and up to a thickness of 3". A sheet of 1.5" material weighs over 300 ponds and costs over $1400. However, it would render about 100 flutes, with a material cost around $14.27 per flute.
I purchased one of their sample boxes and experimented this morning with the largest piece, which is made from several layers of paper dyed in different colors. It requires sharper tooling than I used but turned reasonably well with my dull ones, with just a tiny bit of shallow tear-out which sanded away easily. Boring it was a dream. It produces shavings instead of the continuous ribbon that plastics produce. Finishing went well using my usual sandpaper grades of 120 150 220 320 400 and 0000 steel wool. I further polished it with the automotive rubbing compound TR3 to a nice semigloss.
The Material Data Sheets for this material discuss some of the components used in manufacture but report no untoward results from machining etc. I did not encounter any strange odors etc. when machining this material. I used the usual precautions including an N95 mask.
On Monday I am heading down to their plant in Tacoma and going through a remnant pile to find enough for a flute or some flutes. I have high hopes for this material as something that looks attractive and can be machined into flutes with the practices I currently use. Exciting!
I left these images at full size so that it can be inspected.
Casey

