makeLab™ blog   

Joining | Dog Bone

SUMMARY:

  • A Dog Bone Joint is a friction fit joint used to join two pieces of sheet material.  Typically, dog-bone joints are made using a CNC machine.  They are called dog-bone joints because the corners are rounded out and resemble a cartoon-like bone.  The reason for the rounded out corners is to remove the extra material that is left by a round bit at the corners.
  • When designing a dog-bone joint, it is important to test tolerances with scrap material.  The scrap material should be the same type of material, preferably the same exact material that will be used for the final product.  This is because different materials and even similar materials from different batches can produce different results.  The tolerance needed to create a friction-fit joint is delicate.  You may be able to cut to the exact size of the needed joint, but you may need to add material or subtract extra material to make the joint a tight fit.

MATERIALS:

  • Your choice of cutting material Wood, MDF, etc
  • Desired Rhino/PartWorks File

TOOLS:

cncmachine_iconscrewdriver_iconscrews_icon

  • CNC Machine
  • Screw Driver
  • Screws

SAFETY EQUIPMENT:

icon_earplugs icon_glasses icon_mask

  • Earplugs
  • Safety Glasses
  • Dust Mask

 

CLEAN UP:

dustvacuum_icondustpanmop_icon

  • Power blast dust from machine
  • Use dustpan and mop to clean up floor

READY TO CONTINUE?
Arrow_BackToMenu Arrow_YesContinue

CONTINUE ON TO STEPxSTEP PROCESS

Glossary | Safety

DustMask

Dust Mask: a flexible pad held over the nose and mouth by elastic or rubber straps to protect against contaminants such as dust encountered during activities such as construction

SafetyGlasses

Safety Glasses: protective eyewear (different from regular prescription eyeglasses) that can enclose around the eyes to prevent dust and other particles from agitating and harming the eyes.

EarPlugs

Earplugs: objects covering the ears to protect the ears from hearing lose or foreign objects entering the ear canal.

WeldingMask

Welding Mask: special face mask used to protect the eyes and face from harmful burns and distress from ultraviolight light and sparks

Gloves

Gloves: used to shield the hands from unwanted chemicals or sticky materials

Arrow_BackToMenu

Glossary | Materials

MDF

MDF: Medium Density Fiberboard.  An engineered wood product formed by breaking down hardwood or softwood residuals into wood fibers, combining it with wax and a resin binder, and forming panels by applying high temperature and pressure.

ParticleBoard

Particle Board/Chipboard:  an engineered wood product manufactured from wood chips, sawmill shavings, or even saw dust, and a synthetic resin or other suitable binder, which is pressed and extruded. Particleboard is a composite material.

OSB

OSB:  an engineered wood particle board formed by layering strands (flakes) of wood in specific orientations. In appearance, it may have a rough and variegated surface with the individual strips of around 2.5 x 15 cm / 1 x 6 inch, lying unevenly across each other.

Plywood

Plywood:  a manufactured wood panel made from thin sheets of wood veneer.

Polycarbonate

Polycarbonate: a particular group of thermoplastic polymers that are easily worked, molded, and thermoformed.

AcrylicGlass

Acrylic Glass:  a transparent thermoplastic, often used as a lightweight or shatter-resistant alternative to glass.

ExtrudedPolystyreneFoam

Extruded Polystyrene Foam:  Lightweight, low density foam typically used as insulation for buildings.

 

 

 

Arrow_BackToMenu

Glossary | Tools

CNCMachine

CNC Machine: Computer numeric control.  A computer controlled machine for cutting and removing material.  Typically consisting of two or more axis of movement.

Router

Router: The tool that spins the bit in the CNC machine.

Bit

Bit: Tool that cuts material in a CNC machine by spinning.

ToolHead

Tool Head: The cutting end of the bit.

Shank

Shank: The non-cutting end of the bit.  This is the portion that is held in the collet.

Collet

Collet: The clamping device that holds the bit in the router.

UpcutBit

Upcut Bit: A bit that pulls the removed material up and away from the bit.

DowncutBit

Downcut Bit: A bit that pushes the removed material down and away from the bit.

StraightBit

Straight Bit: The cutting surface is perpendicular to the cutting surface and flat.

LaserCutter

Laser Cutter: A 2-axis cutting machine that uses a concentrated light to burn through material.  The laser cutter is computer controlled.

Spindle

Spindle: The rotating axis of the router in the CNC machine.  This is where the collet and bit are fastened to.

DustCollector

Dust Collector: Vacuum device that collects waste material that is removed from the cutting surface as the CNC operates.

SpoilBoard

Spoil Board: The sacrificial backer that the cutting material is fastened to.

Arrow_BackToMenu

Removing | Mill Plaster

SUMMARY:

  • Milling Plaster is a more precise way to carve into plaster than a dremel tool. When milling plaster it is important to take proper safety precautions and allow PLENTY of time for clean-up. Milled plaster can then be used to create molds or the final piece itself.

MATERIALS:

  • Molded Plaster (steps here)

TOOLS:

cncmachine_iconsandpaper_iconscrewdriver_iconscrews_icon

  • CNC Machine
  • Sand Paper
  • Screw Driver
  • Screws

SAFETY EQUIPMENT:

icon_earplugs icon_glasses icon_mask

  • Earplugs
  • Safety Glasses
  • Dust Mask

CLEAN UP:

dustvacuum_icondustpanmop_icon

  • Vacuum and mop up the CNC room after using (heads up it will look like a blizzard afterwards)

READY TO CONTINUE?
Arrow_BackToMenu Arrow_YesContinue

CONTINUE ON TO STEPxSTEP PROCESS

Forming | WonderCurve

SUMMERY:

  • WonderCurve refers to the process of creating a thin double curve, in this case using Rockite

MATERIALS:

  • Rockite
  • Plexiglass
  • Bubble Wrap
  • Sawdust

TOOLS:

  • CNC Machine
  • Screw Driver
  • Screws
  • Heat Gun
  • Blow Torch
  • Bandsaw
  • Vaseline

SAFETY EQUIPMENT:

  • Earplugs
  • Dust Mask
  • Safety Glasses

icon_earplugs icon_glasses icon_mask

 

CLEAN UP:

  • Vacuum and mop the CNC room after using
  • Let any excess Rockite dry up in the bucket for easy removal and disposal

READY TO CONTINUE?
Arrow_BackToMenu Arrow_YesContinue

CONTINUE ON TO STEPxSTEP PROCESS

Forming | Bubble Mold

SUMMERY:

  • Creating a Bubble Mold refers to the process of creating both the texture and form of bubble wrap. By overlaying either Rockite or Rockhard on the bubble wrap a negative form could be mimicked.

MATERIALS + TOOLS:

  • Rockite
  • Spray Foam
  • Rackhard
  • Bubble Wrap
  • 2″ Foam
  • Vaseline
  • Stir Stick
  • Plastic Bucket
  • Metallic Spray Paint & Glitter (if desired)
  • CNC Machine
  • Screw Driver
  • Screws

SAFETY EQUIPMENT:

  • Safety Glasses
  • Dust Mask
  • Earplugs

icon_earplugs icon_glasses icon_mask

 

CLEAN UP:

  • Vacuum and mop the CNC room after using

READY TO CONTINUE?
Arrow_BackToMenu Arrow_YesContinue

CONTINUE ON TO STEPxSTEP PROCESS

Forming | Plexi Glass

SUMMERY:

  • Plexi Glass can be formed through cutting a positive form on the CNC followed by vacuuming a negative of the form to create a mold. After the mold is constructed a plethora of techniques can be applied to create various results.

MATERIALS + TOOLS:

  • Rockite
  • Wood
  • Polystyrene
  • CNC Machine
  • Vacuum Former

SAFETY EQUIPMENT:

  • Safety Glasses

icon_earplugs icon_glasses icon_mask

 

CLEAN UP:

  • Vacuum and spray down the CNC room after using
  • Brush down sanding area after finished to clean up any dispersed material

READY TO CONTINUE?
Arrow_BackToMenu Arrow_YesContinue

CONTINUE ON TO STEPxSTEP PROCESS

Removing | Cutout MDF

SUMMARY:

  • Cutting MDF consists of using the CNC machine to cut out flat positive sheets from a solid sheet of MDF. Similar principles can also be used for other materials such as various woods, HOWEVER, it is critical to do small scale tests to make sure both the tolerance of the material and bit are ready with the correct settings.

MATERIALS:

  • 3/8″ MDF Whiteboard
  • Desired Rhino/PartWorks File

TOOLS:

cncmachine_iconpalmsander_icon

  • CNC Machine
  • Flat Sander

SAFETY EQUIPMENT:

icon_earplugs icon_glasses icon_maskgloves_icon

  • Earplugs
  • Safety Glasses
  • Dust Mask
  • Gloves

 

CLEAN UP:

dustvacuum_icondustpanmop_icon

  • Power blast dust from machine
  • Use dustpan and mop to clean up floor

READY TO CONTINUE?
Arrow_BackToMenu Arrow_YesContinue

CONTINUE ON TO STEPxSTEP PROCESS

Forming | Aluminum Smelting

SUMMARY:

  • Aluminium Smelting is the process of extracting aluminum from its oxid alumina. This process occurs in three steps; first by creating the kush head pressure tool, followed by constructing the foam and plaster molds, and lastly by forming the kiln out of a propane tank. For each of these steps it is important to keep in mind that the molten aluminum CANNOT come in contact with either water or moisture as it will cause an explosion, and that’s bad.

MATERIALS:

  • 3″ Foam
  • 1.5″ foam glued together
  • Aluminum Scrap Metal
  • Quikrete Concrete

TOOLS:

bucket_icon stirstick_iconpropanetank_icon

  • Bucket and Stirring Stick
  • Propane Tank (for creating the kiln)

SAFETY EQUIPMENT:

icon_glassesweldingmask_iconapron_icongloves_iconclothing_iconsteelboots_iconfireextem_iconpropanetorch_icon

  • Safety Glasses
  • Welding Mask
  • Leather Apron (for potential splashes of molten aluminum)
  • Leather Gloves (for handling molten aluminum equipment)
  • Cotton Clothing (so molten aluminum will roll off rather than burn)
  • Construction Boots
  • Spats (cover the fronts of legs)
  • Fire Extinguisher (for pouring aluminum)
  • TWO Propane torches (for heating the kiln and crucible)

CLEAN UP:

dustpanmop_icon

  • Let kiln and other hot pieces cool down before moving and cleaning

READY TO CONTINUE?
Arrow_BackToMenu Arrow_YesContinue

CONTINUE ON TO STEPxSTEP PROCESS