Instructables
Picture of 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

http://www.techshop.ws

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)
 
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Step 1: Drawing the shape

Picture of Drawing the shape
Photo Dec 27, 3 08 16 AM.jpg
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

Picture of 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

Picture of Cutting the shape
Photo Dec 27, 5 55 34 PM.jpg
After taping your drawing to the MDF board, rough cut your shape on the bandsaw.

Step 4: Using your template

Picture of 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

Picture of 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.
legamin5 months ago

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?

amclaussen7 months ago
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.
lime3D amclaussen7 months ago

It is a sanding table in the TechShop woodshop.

lime3D7 months ago

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.

jjordan207 months ago
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
jjordan207 months ago
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!
Smelter_uk7 months ago
Would have been nice to see it use, and the end product.
joe907 months ago
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.
rkrishnan77 months ago
Beautifully detailed instructions. You obcvously do precision work.
You may wanted to correct a typo: "intractable" for Instructable" Kinda changes the meaning :)
you may want to correct obcvously. i don't know what that is.
HaHa! I stand corrected.
mbode17 months ago
Obviously never made a laminated shape. thanks for the instructable.
what's a laminated shape?
tthompson267 months ago
No idea what this is........
me neither
This is a form/buck for shaping and blending laminate sheets? O.o