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Index
Foreword
Preface
Who Is this book for?
Designers
Fabricators
Teachers
Entrepreneurs
What Can You Do?
How This Book Is Organized
Designing for Fabrication
Virtual Meets Physical
Projects
Resources
What We Left Out
How to Use This Book
Conventions Used in This Book
Using Digital Design Files
How to Contact Us
I. Designing For Fabrication
1. A Modern Way of Making
The Geography of Distributed Making
Why Do CNC Projects Look the Way They Do?
A Very Brief History of CNC Furniture
Join the Revolution
2. End Mill to Furniture Collection
Subtractive Machining
End Mills
Drilling
Cutting Laterally
The Inside Corner Problem
Fillets
Tool Diameter Matters
Exercise: How to Draw Fillets
Dogbones and T-Bones
Sketching Sniglets
Toolpaths
Profile Toolpaths
Outside Profile
Inside Profile
Pocket Toolpath
Drill Toolpath
Drawing Smooth Motion
Eight Basic CNC Joint Conditions
Flat Parts From Sheet Materials
Overlap
Edge to Edge
Edge-to-Edge-to-Edge
End-to-Face
End to Face to Edge
Through
Three-Way
Four-Way
Assemblies
S/Z Joint
Tab Assembly
Hanger Assembly
Corner Assembly
Foot Assembly
Structures
Shear
Torsion
Vierendeel
Rotational
Programs
The 5-30 Minute Chair
Iteration and Design Frameworks
Evolution From the Chair to AtFAB
Rotational Stools
Cat in Bag ii Table
90-Minute Lounge Chair
One to Several Table
Open Storage Cabinet
Poke Credenza
Cellular Screen
AtFAB Furniture Collection
3. 3D Model to 2D Parts
From Design to Fabrication
Mise en Place
Download Files
Layers
Add Layers
Underlays
Draw Sheet Material
Flattening and Layout
Face Right Side Up
Consider Grain Direction
Leave Space Between Parts
Minimize Material Waste
Flatten and Layout Parts
Components
Create Unique Components
Profiles
Make 3D Parts into 2D Profiles
Cutting Layers
Assign Profiles to Cutting Layers
Export Options
Save as SketchUp 2014
Optional: Export a DXF File
4. Getting Started with Design
Define a Project Program
Ergonomics
Fabrication Constraints
File Setup For Design
Layer Naming Conventions
Create File, Add Layers
Draw the Cut Sheet Underlay
Massing Model and Stock Material
Create Massing
Model Material Stock
Standards Versus Proportions
Refine Massing Dimensions
Schematic Design: Model Parts
Copy and Modify Stock, Form Seat
Create Bench Sides
Add Front and Back Parts
Using Reference Lines
Form Legs
Modeling Feet
Form Feet
Evaluate and Analyze
Scale
Iteration
Evaluate and Refine Structure
Add a Center Beam
Organize with Components
Define Components
Flatten Model, Layout Parts
Design Development: Joinery
Joinery Organization
Draw Seat Reference Lines
Draw Sides Reference Lines
Make Joinery
Create Seat Slots
Make Joinery on Front
Make Joinery on Sides
Make Hanger Assembly
Form Foot Assembly
Analyze Bench Joinery
Evaluate Joints
Design Refinement
Evaluate the Overall Design
Sniglets and Fasteners
Draw Sniglet and Hole Components
Model Sniglets
Model Holes
Visualize and Simulate
II. Virtual Meets Physical
5. Precision-Fit Plywood Joinery
Plywood
Selecting Materials
Nominal Thickness
Calipers
How to Digitally Dial In Joinery Fit
Designed for 19mm Plywood
Measure Your Materials
Scale Your CAD File
Scaling, Offsetting, and Parameters
Why Scaling Works
Why Offsets Don’t Work
The Parametric Solution
Prototyping
Partial Prototypes
Test Pieces
Scale Prototypes
6. Machining For Designers
Machining Begins with Material and Tooling
Spindles and Speed
Chip Formation
What Is a Milling Machine?
What Is a Router?
High-Speed Spindles
Machining Variables
Relating Everything to Everything
Where to Begin?
CNC Router Anatomy
Safety
Workholding Strategies
Screws and Clamps
Vacuum Systems
End-Mill Anatomy
Collets
End-Mill Geometries
End Types
Flute Types
Feed Direction
Conventional Cutting
Climb Cutting
Feed Direction Strategies
Ramp Moves and Tabs
Smooth Ramps
Spiral Ramps
Tabs
Pockets
Offset
Raster
Stepover
Depth of Cut
Putting It All Together
Troubleshooting
7. Modeling Software to Machine
From CAD to CAM
Digital/Physical Alignment
Units
VCarve Pro
Download and Install
Open VCarve and Create a New File
Job Setup
Job Type
Job Size
Z Zero Position
XY Datum Position
Design Scaling
Modeling Resoluton
Complete Setup
Importing Vectors
Import Stools SketchUp File
Layout of Imported Data
Create Circles/Arcs
Component/Group Handling
Data to Import
Vector and Layer Adjustments
Align Cut file to material stock
Ungroup Vectors
Join Open Vectors
Creating Profile Toolpaths From Vectors
Rotational Stools Toolpaths
VCarve’s Multi-Menu Interface
Fastener Hole Toolpaths
Select Profile Toolpath Operation
Open the Tool Database
Select 1⁄8″ Tool
Cutting Depths
Start Depth (D)
Cut Depth (C)
Edit Passes
Machine Vectors
Name and Calculate Toolpath
Simulate Toolpaths
Seat Inside Profile Toolpaths
Select Profile Inside Vectors
Create Seat Inside Profile Toolpaths
Simulate Inside Profiles
Outside Profile Toolpaths
Turn On Layer, Select Vectors
Select ¼″ Tool
Create Outside Profiles
Simulate Outside Profiles
Adding Ramps
Add Smooth/Spiral Ramps
Toolpath Order
Define Cut Sequence
Simulation and Analysis
Visualize and Analyze
Quality Control
Save Toolpaths for Fabrication
Toolpath Summary
Save Toolpaths to File
Ready to Fabricate?
8. Rotational Stools
About the Design
Before You Begin
Measure and Scale
Cut and Evaluate Fit
Evaluate the Lazy Stool
Evaluate the Lively Stool
Troubleshooting
Measure
Analyze
Adjust
Evaluate and Iterate
Assemble
Fasteners
How to Drill
9. Cat In Bag ii Table
About the Design
Before You Begin
Finishes for CNC Projects
Partial Prototyping: Using a Test Piece
Measure and Scale
Measure Material
Scale Test Piece CAD file
Assign CAM Settings
Evaluate Your Test Piece
Prototyping Finishes
Record Settings and Adjustments
Apply Test Piece Settings to the Full-Scale File
Cut and Finish
Assembly
III. 2D & 3D Modifications
10. 5-30 Minute Chair
About the Design
Before You Begin
Develop a Program
Select Materials
Design Decisions: 2D and 3D Modifications
2D Design Transformations
3D Design Transformations
Working with Scale Prototypes
Exercise: Transform the Chair into a Bench
Measure and Scale
Create the Partial Prototpye
Prepare File
Prepare Toolpaths
Cut, Assemble, and Evaluate
Adjust and Cut Chair
Assemble
11. 90-Minute Lounge Chair
About the Design
Before You Begin
Select Materials
Design Decisions: 2D and 3D Modifications
2D Modifications
Exercise: 3D Transformations
Measure & Scale
Partial Prototpye
Prepare Toolpaths
About the Pockets
Create Pocket Toolpaths
Simulate
Cut Sequence for Complex Parts
Pocket Cutting: Top Down or Bottom Up?
Assemble and Evaluate the Test Piece
Evaluate Fit
Evaluate Cut Depth
Adjust and Cut Chair Files
Assemble
Using the Jig
IV. Parametric Transformations
12. Parametric Design
What are Parameters?
AtFAB’s Parameters
Tool Diameter
Material Thickness
Shape
Module
Dimensions
Details
Designing Parameters
Parametric Case Study: the Cat in Bag ii Table
Functions, Variables, and Limits
Parametric Processing Applets
Installing and Using the Apps
13. One to Several Table
About the Design
Before You Begin
Establish a Program and Dimensions
Select Materials
Parametric Transformation
Parametric Design
Using the One to Several Table App
Set Overall Conditions
Prepare CAD File
Measure & Scale
Create the Partial Prototpye
Prepare File
Prepare Toolpaths
Cut, Assemble, and Evaluate
Adjust and Cut Table
Assemble Table
14. Open Storage Cabinet
About the Design
Before You Begin
Establish a Program and Dimensions
Select Materials
Measure Two Materials
Find TCMAX
Find TDMAX
Parametric Transformation
Using the Open Storage app
Set Overall Conditions
Prepare CAD File
Layout Parts
Prepare for CAM Import
Calculate the Scaling Multiplier
Scale Toolpaths
Create a Partial Prototpye
Prepare File
Prepare Toolpaths
Cut, Assemble, and Evaluate
Adjust Cabinet Files and Prepare for Cutting
Cut Pockets on the Correct Side
Cut Cabinet
Assemble
V. Moving Parts and Large Structures
15. Poke Credenza
About the Design
Before You Begin
Materials
Patterns and Modifications
What to Draw?
Measure and Scale
Create the Partial Prototpye
Prepare File
Adjust Slots
Prepare Toolpaths
Prepare Toolpaths for Sliding Doors
Cut Sequence
Cut, Assemble, and Evaluate
Adjust and Cut Credenza
Cut on the Correct Side
Assemble
16. Cellular Screen
About the Design
Before You Begin a Large Project
Materials
Manage Parts
Measure & Scale
Scale CAD file & Test Piece
Partial Prototyping Large Projects
Create the Partial Prototpye
Screen: Multi-Sheet Workflow
Assign toolpaths to each sheet
Cut Screen File and Stage Parts
Assemble the Screen
VI. Resources
A. Design Resources
Design Repositories
Recommended Reading on Design
Design Thinking
Open Design
Parametric Design
Human Factors and Ergonomics
B. Sourcing Materials
Tips
Materials We Like
Plywood and Other Sheet Materials
Coatings & Finishes
Hardware resources
Sheet Materials Beyond Plywood
Engineered Wood Sheeting (MDF & OSB)
High-Density Polyethylene (HDPE)
Composites
Acrylic
C. Machining Resources
Bibliography and Recommended Reading on Routing
Tool Vendors
Tool Recommendations
Glossary
Index
About the Authors
Acknowledgments
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