Most CAM software will take in the the surfaces and wire frame from the step file. If you make a drawing from the part and add a note telling the moldmaker that it is a .05 X .05 retangular pattern buy how many in the X and how many in the Y all you have to do is model a few of the bristles for the shape of them, any good molder can read the drawing along with the model. Trust them.
if you also save an iges, you can check a box that will include sketches. the more you send the more options the toolmaker has to complete the job.
and if the molder has SW or the CAM software that can read the SW file directly they'll be able to do even more. Surfcam can read SW parts and get all the sketch geom on its own layer, do this every day.
Lenny, Thank You for your response. Along with SW files and STEP, I will provide an iges file, to include the sketch points. I have already provided details for bristle spacing in X and Y in a sample area, as you suggested. However, I am creating letters by having bristles omitted to form the letters. And the corners are rounded so more bristles will be omitted in corners, to follow the rounded shape. I feel a model with sketch points, or a sketch overlay with all the points will show the mold maker where a bristle is/is not to be formed, rather that dimensioning stop/start of bristles that form the letters.
1) Are they referred to as "bristles"? Want to get my terminology right.
2) How are all those "bristles" made? I am assuming holes are drilled in mold half. I was also told that sometimes bristles are formed by having a bed of round pins, and the space between the pins is what forms the bristles. sounds more complicated to me. The bristle diameter is .02" with a .05" spacing, so I don't see how that would be possible.
so from what you have said, you have a name and the the bristles fit inside the letters?
as for making the parts and molding I don't know how that is done, not a mold maker, model makers yes, but not mold.
I have just used SW and CAM and machining for 25 yrs and know a lot of tricks to get the files to others or to me.
call a mold shop and see how bristles are molded is your best course of action.
The name is formed from the area void of bristles.