Bent Lamination Form (How To)




Posted in WorkshopFurniture

Introduction: Bent Lamination Form (How To)

In this intractable, you will learn how to create a bending form for bent lamination. I made it at TechShop

What you will need:

1. Metal ruler (3ft)
2. Heavy objects
3. French curves
4. Drafting & design fade-out vellum (drafting paper)
5. Blue painters tape
6. Number 2 pencil
7. Bandsaw
8. Drill (with Philips tip)
9. Drillbit for pilot holes
10. Drywall screws (2in)
11. Wood clamps
12. MDF board (3/4in) - With and height depend on your project
13. Birch plywood (thickness - 3/4in) (width - 2ft) (length - 2ft)
14. Wood router (Flush trim bit with bearing on top)

Step 1: Drawing the Shape

Draw you shape with your number 2 pencil using the french curves for small curves, your metal ruler and heavy objects for your big curves, and your metal ruler for straight lines.

Step 2: Accurate Measurements

It's important to first create a series of points with your ruler so that you shape lines flow smoothly, as illustrated below.

Step 3: Cutting the Shape

After taping your drawing to the MDF board, rough cut your shape on the bandsaw.

Step 4: Using Your Template

After using an oscillating sander to clean up the inner curves and a disc sander to clean the outer curves, trace your shape to another MDF board using your sanded shape and then rough cut the same shape only this time leave at least 1/16 of an inch between your cut and your pencil line. Next clamp both shapes together making sure the bottom of the boards are flush and that the new shape sticks out at least 1/16 of an inch past your template shape. Its also, helpful to use screws to make sure the two pieces of MDF board don't shift.

Step 5: Flush Trim Routering

Next attach your flush trim bit to your router and run the router along your template shape. Make sure to keep your router flat and level to your template piece. It make take multiple passes to get your shapes flush. The key is to take your time and don't rush.

Step 6: Inside Cutout

Using your ruler or tape measure, create a series of marks 4 inches from the shaped edge of your board. Then using your french curves and metal rules add in the curves as best your can. It's not important that the pencil line match your shape exactly unless your a perfectionist like me.

Step 7: Matching the Pieces

Cut the pencil line using a bandsaw, and then trace and cut the same shape on your other piece like so.

Step 8: Attaching the Inner Blocks

Next, rough cut block to fit between your shapes. It's better to cut them too big and sand them down with the disc sander or oscillating sander. Then clam your blocks to your first piece and screw them together. Be sure to drill a pilot hole first for each screw. It also helps to counter sink each hole to keep your screws flush with the MDF board.

Step 9: Final Step

Next attach your second piece in the same way. I like to use a carpenter's square to make sure the pieces match up. Once both pieces are screwed together, it's a good idea to clean the whole piece up with the disc sander and oscillating sander. This insures the piece is as flush as possible. I also like to cover the shape with cellophane tape so that my laminates don't stick to the shape.

And that's it your all done.



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    cool, simple and clean! A l lot of beginners will owe their start to you! ( and I owe my new tool bench build to you! What a great design?

    Apart from not telling us the end purpose of the form, could you please tell us what's the purpose of the very elaborated bench surface that appears on the pictures? (It looks like another Instructables project itself!). Amclaussen.

    1 reply

    It is a sanding table in the TechShop woodshop.

    Since you are a member of TechShop, you can import a CAD drawing into the VCarve software, and cut the shapes on the ShopBot. This will eliminate the need to draw the shapes by hand, and the ShopBot will give you a much cleaner edge.

    and that elaborate surface looks like a downdraft table for sanding on. It has a vacuum from underneath, and the grooves direct it towards the middle where the chute is

    It's a form to clamp thin layers of wood strips to when laminating(gluing together several layers). Clamp to the form, let the glue dry, and you got a shape!

    Would have been nice to see it use, and the end product.

    Nice instructable and well described. However, I fail to understand what is the purpose of this form - Could you please show examples of its use? Thanks.

    Beautifully detailed instructions. You obcvously do precision work.
    You may wanted to correct a typo: "intractable" for Instructable" Kinda changes the meaning :)

    2 replies

    you may want to correct obcvously. i don't know what that is.

    HaHa! I stand corrected.

    Obviously never made a laminated shape. thanks for the instructable.

    1 reply

    This is a form/buck for shaping and blending laminate sheets? O.o