gabriel stacey-chartrand

Week 07: computer-controlled machining

Tile geometry inspiration

My design explorations were informed by tile geometries. The goal was to maximize material use and minimize waste.

I wanted:

tile geometry inspiration
cutting cardboard shapes to test tile geometry

Using illustrator to design tile geometries

The process of trying to find a geometric layout that outputs functional pieces for a 3D set of objects was a really fun puzzle to solve.

testing different tile geometry configurations in Illustrator
the specific Barcelona panot that I took inspiration from
final tile geometry design process in Illustrator
explored a different leg orientation for a similar design
final tile design for patio set

Developing the final design in Fusion

I created a fully parametric sketch of my tile design using Fusion.

step 01 of the Fusion sketch
step 02 of the Fusion sketch
final constrained Fusion sketch
final CNC layout in Fusion
final rendering of the panot patio set - view 01
final rendering of the panot patio set - view 02
final rendering of the panot patio set - view 03
setting kerf offset lines in Rhino to adjust joint dimensions

Adding dogbones and screw hole locations

Due to my edge-to-edge layout, I had to find small unused pieces within my design to add screw locations in order to secure the piece to the bed. I also added an abundant amount of bridges to make sure that all pieces were always interconnected.

manually adding dogbones to all joints in Rhino
running a Rhino CAM simulation
setting the perfect zero on the CNC mill - view 01
setting the perfect zero on the CNC mill - view 02
CNC milling process - engraving the workpiece

Self-destruction: a lesson

When I re-exported the NC files from Rhino CAM, I must have accidentally selected the screw holes which were also set to an engraving operation. When I pressed play for the engraving operation, the machine suddenly decided to destroy itself.

self-destruct incident with the CNC bit

The bit was nowhere and everywhere at the same time.

self-destruct incident with the CNC bit - resulting hole

Back to cutting

Removal

removing pieces using chisel
all pieces removed from bed

Post-processing

using a router to remove bridges from the pieces

I discovered that I made a mistake on one half of the tool stands when I adjusted for kerf. I needed to cut 3mm off some of the joints with a hand saw.

post-process correction using a hand saw to fix joint dimensions

Final assembled panot patio set

final assembled panot patio set
3d nesting
3d nesting

Next steps in post-processing

Windproof furniture explorations

Using holes in faces of furniture and using hole circles as dividers for vertical stacks

Under construction.

Suntray (for humans)

Under construction.

Country roads...