n-Hedral – Behind the Scenes, Part 1: Rapid Prototyping

June 4, 2014 Experiments
If you haven’t yet checked out my Masters Project, n-Hedral: Customizable Furniture System, take a look here!

After going through a couple iterations of joint designs for the n-Hedral system, I finally landed on something that looked like it would work:

  • Joint sketch, with connector.

I had and assembly of the design, however, I needed to see whether the joint would be strong enough.  So I decided to quickly make one with some sheathing plywood I had laying around.  My Shapeoko only has a 7″ x 7″ working area, so that would mean I’d have to make each component cut separately.  To save time, I used hand tools to cut out the panels.  Using my trusty circular saw, jig saw, and drill with forstner bits, I created the general shape of the panels.  Then I finished off the notches with a chisel and mallet.

  • The finished panel set after drilling. Next step is to remove the pocket material.

While I was doing this, I had my set of connectors printing on my Makerfarm Prusa i3:

  • Printing the prototype connector pieces.

Once completed, it was time for assembly:

  • The trim pieces were secured with a nail.

In about 4 hours of work, I was able to produce a proof-of-concept prototype.  Complete with custom connectors and all.  From here, I was able to move forward and refine the design slightly, and then move into final prototyping.

  • Final prototype assembly.

Click here to see the next installment of n-Hedral – Behind the Scenes!

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