My client is aksing me if I can manufacture a small but long strip-shaped aluminum-alloy (7075 T651) part. The sectional dimension is about 15mm by 12 mm and the length is about 1000mm. Ideally, this part shall be made as extrusions. However, the client just needs one piece of the product, so he asks me if I can manufacture this product by milling. The main problem is that there's a through slot in the lengthwise direction, and the wall is very thin, about 1mm. The process I come up with is that I mill the slot first when much stock is left around it and hence the wall is thick enough, and then fill something into the slot so as to maintain/increase the rigidity of the part for the next milling process.
So my question is: which material shall I use?
Ideally, this material should adhere/stick to the metal part, and more importantly, it is easy to be removed from the part after I finish all processes. Maybe paraffin wax is a candidcate, but I suspect if it's strong enough. Someone suggested I use PVC soldering rod, but I tried and failed. It didn't stick to the part. I also considered expoxy resin, but it's not easy to be removed and cleared from the part.In thi case, I may need to polish the slot remove the resin. That would be annoying. Can someone here shed light on the material selection? Thank you very much.