makeLab step X step

Over the past academic year the makeLab has worked to document and catalogue a step X step reference for common digital fabrication processes.  With the help of students James Cole, Erika Zajac and Nicholas Green the new section is now online.  This initial release serves as a starting point and more processes will build overtime.

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makeLab step X step was partially funded by the Architecture Research Centers Consortium (ARCC) incentive grant.

Forming | Jig

SUMMARY:

  • A Jig is a custom-made tool used to control the shape or location of another tool. In this example the jig is used to form and bend the piece of wood into a unique shape.

MATERIALS:

  • Desired Rhino/PartWorks File
  • Plywood
  • Water/Steam

TOOLS:

cncmachine_iconscrewdriver_iconscrews_iconclamp_icon

  • CNC Machine
  • Screw Driver
  • Screws
  • Clamps

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?
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CONTINUE ON TO STEPxSTEP PROCESS

Forming | Double Curved Mold

SUMMARY:

  • Double Curved Molds allow for a fully considered object. By being able to control both sides, the architect is able to fully conceive their three-demential concept. Use caution, like the double sided mill, this process is also a tricky one.

MATERIALS:

  • Rockite
  • Plexiglass
  • Sawdust
  • Vaseline

TOOLS:

cncmachine_iconscrewdriver_iconscrews_iconstirstick_iconbucket_icon

  • CNC Machine
  • Screw Driver
  • Screws
  • Stir Stick
  • Bucket

SAFETY EQUIPMENT:

icon_glassesicon_earplugsicon_earplugs

  • Safety Glasses
  • Dust Mask
  • Earplugs

 CLEAN UP:

dustpanmop_icon

  • Use dustpan and mop to clean up floor

READY TO CONTINUE?
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CONTINUE ON TO STEPxSTEP PROCESS

Forming | Vacuum Mold

SUMMARY:

  • Vacuum Molds allows almost anything to become a mold. Typically, shapes are milled out first, however the vacuum can be made to surround almost anything making your casting possibilities endless.

MATERIALS:

  • Wood (for milling, or other found object for casting)
  • Polystyrene
  • Rockite

TOOLS:

cncmachine_icon palmsander_iconbucket_iconstirstick_icon

  • CNC machine
  • Vacuum Former
  • Sander
  • Bucket
  • Stir Stick

SAFETY EQUIPMENT:

icon_glasses icon_maskgloves_icon

  • Safety Glasses
  • Dust Mask
  • Gloves

 CLEAN UP:

dustpanmop_icon

  • Use dustpan and mop to clean up floor

READY TO CONTINUE?
Arrow_BackToMenu Arrow_YesContinue

CONTINUE ON TO STEPxSTEP PROCESS

Forming | Pressed Plexi Glass

SUMMARY:

  • Pressed Plexi Glass is formed by placing a heated piece of polysterne between two molds. These molds can either be found or milled on the CNC machine. This is a quick process that can be repeated as needed.

MATERIALS:

  • Polystyrene
  • mold (possibly milled earlier)

TOOLS:

cncmachine_iconheatgun_iconpalmsander_icon

  • CNC Machine
  • Heat Gun
  • Power Sander

SAFETY EQUIPMENT:

icon_glassesgloves_iconicon_earplugsicon_mask

  • Safety Glasses
  • Gloves
  • Ear Plugs
  • Dust Mask

CLEAN UP:

dustpanmop_icondustvacuum_icon

  • Clean up around sander when finished
  • Vacuum and spray down the CNC room after using

READY TO CONTINUE?
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CONTINUE ON TO STEPxSTEP PROCESS

Joining | Linear Wave

SUMMERY:

  • This process allows for a great allotment of improvisation. For the example displayed here the team generated and mapped this form digitally beforehand, however upon creation allowed for slight variation and improvements along the way. Though wood and rope were the selected materials for our display process, don’t let that limit you in exploring new avenues and building upon this concept.

MATERIALS:

  • Wood
  • Eye Bolt
  • Plastic Expander
  • Rope

TOOLS:

heatgun_iconhammer_icon

  • Heat Gun
  • Hammer

SAFETY EQUIPMENT:

gloves_icon

  • Gloves

CLEAN UP:

dustpanmop_icon

  • Use dustpan and mop to clean up floor

READY TO CONTINUE?
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CONTINUE ON TO STEPxSTEP PROCESS

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

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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.

 

 

 

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