Make something BIG using CNC machine

PresSeat!

The exercise of this week assignment has been very exciting for me. After the knowledge I got during week3, concerning pressfit kit, I decided to model a bench for both indoor and outdoor use. Since I was not sure about the material thickness and kerf dimension, I used Grasshopper to create a parametric model, so that I could have the possibility to change values and not lose time to fix the model.

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Concept

I started by sketching some concept and model in 3ds max just to understand the shape. I just worked on design in this step.

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Parametric Model

Shapes and curves I have made in Grasshopper are related to the movements of the machine, creating the real path for the kerf. In the following video I show how the definition works.

Here a sample model I have loaded on SketchFab. It is just to understand the real outcome. Actually only the curves are useful for cutting process.

DOWNLOAD FILES

Rhinoceros file
Grasshopper definition

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Model

With the epilog, I create a model to check the joints and the model itself. I have left no interference for this process, but one the real size file I have applied 0.5mm of interference, since the OSB remains after cutting can obstruct assembly.

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Nesting and Cutting

For cutting process we have been helped by DREAM FABLAB (Design and REsearch in Advanced Manufacturing), in Naples. Since we had 1200x1200 SOV panels, I made the nesting using 2 boards. Then I exported in .dxf file and worked with DELTACAM.

First of all, we have to set the board extensions, which in my case was 1220x1250mm. After that I have set the milling machine point, which was 6mm diameter.

Then, I set the first curves to mill, the internal one.

Here I have applied the tabs. Since I set 3 cutting layers to reach the depth of 18mm (7mm-7mm-4mm), the tabs will be milled during the third and last layer, so that the tan thickness is 4mm, easy to remove after.

Here I set the origin (relative)

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Make something BIG in another country

I had the chance to go to FabLab77, in Moscow, Russia. This Fablab is situated is the MISIS UNIVERSITY OF TECHNOLOGY and it provides a lots of services and machines. I came with my grasshopper definition, because I did not know the diameter of the miller and the wood panel in there. With the help of Dyma, who was very polite and professional, I set my curves in order to cut a 18mm thickness plywood, with a 6mm kerf miller. Once we have discussed about the the correct curves, I exported the files and give to Dyma, so that he could process the file for milling, choosing a non-offset path since my curves represent the miller center path.








An interesting note is that there is no need to fix the board on the platform, thanks to a vacuum system with provides grip between the wood panels and the machine.





It took just 1 hour to cut all the shapes and 1 more hour to polish all the pieces. Prices are not so different from Italy. Each hours costs approximately 32 euros (2000 Rubles) and the plywood board (1,5x3m) around 55 euros (3500 rubles).



THIS IS THE FINAL RESULT

Make something BIG and partecipate to a competition

After these experiences with cnc machines and process, I have applied for a design competition in my region. After being shortlisted, they chose me among the winners of Settimana del design campano. Lots of people appreciated not only the design, but expecially the process and the parametric joints, without using screws or bolts.