Design and Modeling Process in Rhinoceros

Initial Setup

  • We created a new file in Rhinoceros and defined the working environment.
  • The construction plane was selected as the base for the modeling process.
  • Basic geometries were generated using the line tool to define the initial structure.

Modular Design Development

  • The furniture was designed as a modular system composed of 10 pieces.
  • All elements were designed to be assembled without screws.
  • A foam cushion was incorporated in the seating area to improve comfort.

Dimensioning and Material Definition

  • General dimensions of the model were established.
  • A material thickness of 15 mm was defined to ensure accurate joints and fittings.
  • This parameter was essential for CNC fabrication precision.

Ergonomic Criteria

  • The furniture height was defined based on ergonomic standards.
  • For children between 3 and 5 years old, a height of approximately 53 cm was considered.
  • This ensures proper usability and comfort for the target users.

Structural Elements

  • Two lateral profiles were generated as the main structural components.
  • These elements define the overall shape and provide stability to the furniture.
  • They act as the base structure for assembling the remaining parts.

Digital Assembly Verification

  • The first digital assembly of the model was performed to verify that all joints and dimensions were correct.
  • This step allowed us to detect possible fitting errors and inconsistencies in the design before fabrication.
  • The assembly process helped confirm that the modular connections functioned properly without the need for additional fixing elements.
  • It also provided a clear understanding of how each component interacts within the system.

Extrusion of the Components

  • After validating the 2D design, all the pieces were extruded to generate the three-dimensional model.
  • The extrusion was performed considering the real material thickness (15 mm), which is essential for accurate CNC fabrication.
  • This step ensures that all joints and interlocking elements correspond precisely to the physical material dimensions.
  • By converting the 2D geometry into 3D elements, we were able to better visualize the final structure and evaluate spatial relationships between components.
  • This process also helped to identify potential geometric conflicts before proceeding to fabrication.

Complete Model Assembly

  • The complete assembly of the model was verified to ensure that all the pieces fit correctly.
  • This step allowed us to evaluate the structural stability and overall coherence of the design.
  • It confirmed that the modular system works efficiently without the use of screws or additional hardware.
  • Additionally, the full assembly provided a realistic preview of the final product.

Layout Optimization for CNC Cutting

  • Once the structural modeling was completed, the design was organized within the working board.
  • This layout serves as a reference for the CNC cutting process.
  • The arrangement of the pieces was optimized to maximize material usage and minimize waste.
  • This step is essential to ensure efficiency in fabrication and reduce production costs.
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Concept Sketch Development

  • Following the design workflow, a conceptual sketch of the furniture was developed.
  • Special attention was given to the dimensions of the lateral joints to ensure proper support of the seat.
  • This step allowed us to refine the design before proceeding with detailed modeling.
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Base Design

  • The bases of the furniture were designed considering both internal and external joints.
  • These connections ensure proper assembly between all structural elements.
  • The design guarantees stability and ease of assembly.
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Structural Design Refinement

  • The structural design was further developed by defining the main contact points.
  • Necessary joints were incorporated to ensure stability and resistance.
  • This step reinforces the overall structural integrity of the furniture.
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Layout Optimization

  • All design components were organized within the working board.
  • The pieces were aligned and distributed to optimize material usage.
  • This step helps to minimize waste during the CNC cutting process.
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File Selection and Export

  • To finalize the design process, only the required components were selected.
  • The “Export Selected” option was used to export exclusively the necessary elements.
  • This step ensured that only relevant geometries were prepared for the CNC fabrication process.
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DXF File Export

  • The file was exported in AutoCAD DXF format.
  • This format is compatible with CNC machining software and allows precise transfer of geometries.
  • The export process ensures that dimensions and vector paths remain accurate for fabrication.
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CNC Machining Process

File Import in Vectric

  • Vectric software allows the import of DXF files generated during the design phase.
  • This software is used to configure cutting tools, machining parameters, and toolpaths.
  • It defines the movements that the CNC machine will follow during the fabrication process.
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Machine Zero Calibration (X and Y Axes)

  • The milling tool must be positioned at the reference point closest to the workpiece zero.
  • Once positioned, the zero point is set for the X and Y axes.
  • This step ensures correct alignment between the digital model and the physical material.
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Tool Positioning and Z-Axis Calibration

  • The control interface allows movement of the tool along different axes.
  • The machine zero can be adjusted manually using the control system.
  • The Z-axis is calibrated using a measurement probe to ensure accurate cutting depth.
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Loading the Machining File

  • The machining file is loaded using the “Cut Part” option.
  • The corresponding file is selected for execution.
  • This file contains the toolpath instructions generated during the CAM process.
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File Saving Format

  • Once all configurations are completed, the file is saved with the .sbp extension.
  • This format is compatible with the ShopBot CNC machine.
  • It ensures proper communication between the software and the machine controller.
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Material Setup

  • The working board is configured by defining its dimensions in the X and Y axes.
  • The material thickness is also specified.
  • The position of the workpiece zero is established according to the selected reference point.
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Vector Import

  • The vectors to be machined are imported into the software.
  • These vectors define the geometry that will be cut by the CNC machine.
  • Proper verification ensures that all elements are correctly positioned.
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Toolpath Visualization and Cutting

  • The software allows visualization of the toolpath before machining.
  • This preview helps verify the accuracy of the cutting process.
  • Once validated, the machining process is executed.
  • After cutting, the components are ready for assembly.

Results

Furniture Assembly

  • The final assembly of all furniture components was successfully completed.
  • The modular system allowed an efficient assembly process without the use of screws.
  • All joints and connections fit accurately, confirming the precision of the CNC fabrication.
  • As an aesthetic detail, the edges of the wood were painted in violet to enhance the visual appearance and provide a more uniform finish.
  • A foam cushion upholstered with pink fabric was incorporated into the seating area to improve comfort.
  • The cushion was fabricated and sewn using laboratory sewing machines, ensuring a higher quality finish.

Conclusion

  • In this project, we successfully designed and prepared a modular children’s furniture piece using parametric design principles.
  • Ergonomic criteria were effectively integrated to ensure usability and comfort for the target users.
  • The process allowed us to understand the importance of proper machining parameter configuration.
  • Accurate setup of CNC parameters ensured precise assembly and high-quality results.
  • Material optimization strategies contributed to reducing waste during the fabrication process.
  • This practice reinforced the relationship between digital design and physical manufacturing.