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Step 3Interlocking Tooth Design
The first design that I decided to evaluate was the cube using interlocking teeth. This is where teeth at the edge of a cube mesh together to hopefully construct a cube that does not collapse.
There were two aspects that I wanted to experiment with: the first being the material, and the second being the tooth fitting process.
The first picture shows the pieces cut from 6mm Eurolite ply wood. You may notice that each of the teeth bow outwards slightly on one side. This is to allow for the laser cutting kerf and create a tighter fit (also shown in picture 2, an Inkscape design).
Picture 3 shows the fitted ply wood pieces constructed into a cube. Picture 4 shows the same design in 6mm black acrylic. Picture 5 compares 3mm green acrylic.
If you don't allow for fitting and cut straight from the SketchUp design you end up with a functional cube, but as picture 6 shows, the pieces come apart very easily (not a problem if you are going to use glue).
Instruction 3a: If using interlocking teeth, allow for fitting in 2D or buy some glue.
As the video below shows, putting the pieces together can be quite tricky (6mm Eurolite ply wood is shown).
Instruction 3b: If required, label your pieces for faster assembly (or to account for personal stupidity).
Once the cube is constructed, you can see that it holds its form quite well. The fitting needs to be tweaked a little as the pieces do feel a little loose even though it is meant to be taken apart.
SUCCESS!
The next video shows the same fitted design used with 6mm black acrylic with the same effect.
Instruction 3c: The interlocking teeth design can be used with both wooden and acrylic materials for similar results (although ply wood is sooo much prettier).
SUCCESS!
In terms of aesthetics it is really up to the individual to choose the right material. I am partial to the ply wood as is gives a range of tones in the grain and also in the cut ends. I like the thin acrylic because it refracts light, but I'm not a fan of the black acrylic because it hides the joins and is flat; however, it could be quite effective if using etching to outline borders and add graphics.
Instruction 3d: Consider the joins, tones, light, and etching when choosing a material (i.e. what will look prettiest).
The cost difference between a fitted cube design ($4.95USD*) and unaltered cube design ($3.30USD*) is $1.67USD* (*pricing on 1st August 2008 for "making" costs using 6mm Eurolite ply wood). This difference is because the number of cut lines can be reduced with an unaltered design (pieces share common edges see picture 7). In terms of time, it is quicker to produce an unaltered design, but manually intensive to glue together. A fitted design takes longer to perfect in Inkscape, but takes the hassle out of construction (my preference).
Instruction 3e: Take into account the cost in terms of design time, construction time, and sundries like glue, as well as the laser cutting cost. The same design on different materials will also affect the laser cutting cost.
Before moving to the next design take a moment to inspect picture 8, the original SketchUp design. It shows that the SketchUp-to-Inkscape-to-Ponoko pipe line is working!
SUCCESS!
There were two aspects that I wanted to experiment with: the first being the material, and the second being the tooth fitting process.
The first picture shows the pieces cut from 6mm Eurolite ply wood. You may notice that each of the teeth bow outwards slightly on one side. This is to allow for the laser cutting kerf and create a tighter fit (also shown in picture 2, an Inkscape design).
Picture 3 shows the fitted ply wood pieces constructed into a cube. Picture 4 shows the same design in 6mm black acrylic. Picture 5 compares 3mm green acrylic.
If you don't allow for fitting and cut straight from the SketchUp design you end up with a functional cube, but as picture 6 shows, the pieces come apart very easily (not a problem if you are going to use glue).
Instruction 3a: If using interlocking teeth, allow for fitting in 2D or buy some glue.
As the video below shows, putting the pieces together can be quite tricky (6mm Eurolite ply wood is shown).
Instruction 3b: If required, label your pieces for faster assembly (or to account for personal stupidity).
Once the cube is constructed, you can see that it holds its form quite well. The fitting needs to be tweaked a little as the pieces do feel a little loose even though it is meant to be taken apart.
SUCCESS!
The next video shows the same fitted design used with 6mm black acrylic with the same effect.
Instruction 3c: The interlocking teeth design can be used with both wooden and acrylic materials for similar results (although ply wood is sooo much prettier).
SUCCESS!
In terms of aesthetics it is really up to the individual to choose the right material. I am partial to the ply wood as is gives a range of tones in the grain and also in the cut ends. I like the thin acrylic because it refracts light, but I'm not a fan of the black acrylic because it hides the joins and is flat; however, it could be quite effective if using etching to outline borders and add graphics.
Instruction 3d: Consider the joins, tones, light, and etching when choosing a material (i.e. what will look prettiest).
The cost difference between a fitted cube design ($4.95USD*) and unaltered cube design ($3.30USD*) is $1.67USD* (*pricing on 1st August 2008 for "making" costs using 6mm Eurolite ply wood). This difference is because the number of cut lines can be reduced with an unaltered design (pieces share common edges see picture 7). In terms of time, it is quicker to produce an unaltered design, but manually intensive to glue together. A fitted design takes longer to perfect in Inkscape, but takes the hassle out of construction (my preference).
Instruction 3e: Take into account the cost in terms of design time, construction time, and sundries like glue, as well as the laser cutting cost. The same design on different materials will also affect the laser cutting cost.
Before moving to the next design take a moment to inspect picture 8, the original SketchUp design. It shows that the SketchUp-to-Inkscape-to-Ponoko pipe line is working!
SUCCESS!
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