R.A.W Pattern Maker Cardboard

We

• Anton Lenssens
• Wiebe Van Gansbeke
• Robin Vandermeersch

are students Industrial Product Design at the Howest.

For an assigment we had to work in team to create a pattern maker for processing of carboard.

If you want to see our whole proces of how we became it's final design, you can find us on our blog:https://patternmaker10.wordpress.com/2017/01/04/fi...

Here you can see step by step how we did it and build it yourself.

Good luck!

Step 1: Materials & Tools

1. Materials

• Beams of steel ■35cm (±350cm)
• Pipes of steel ø17mm (±70cm)
• Pipes of steel ø19mm (±180cm)
• Axis of steel ø8mm (±24cm)
• MDF plate 100cm x 37cm x 1,8cm
• 4 L-Profiles 10cm x 10cm x 2mm
• 2 L-profiles 15cm x 8cm x 2mm
• 4 doorlocks (picture)
• Sawblades (100cm)
• bolts and nuts M6
• bolts and nuts M8
• PVC sheet 30cm x 30cm x 2mm
• PVC sheet 30cm x 50cm x 12mm
• Polycarbonate 40cm x 30cm x 2mm
• 3D printed parts (STL-file attached)
• Rubber sheet 30cm x 30cm x 5mm
• Bearings (8x) ø22mm
• Roundels ø8

2. Tools

• Basic tools lik saw, drill ...
• Welding machine
• 3D printer
• Pipe bender
• Milling machine
• Thread divice

Step 2: Frame

First you have to weld a frame out of the beam of steel. Everything is going to be attached to this part so it has to be heavy en very strong to whitstand all the forces of the machine.

You can find the dimensions in the file.

Step 3: Rotating Point

For this step you have to make a little beam which will later be attached to the handle.

You can find the dimensions in the file.

Step 4: Handle

For this step you have to make a handle. Use different types of pipes for this step.

First you have to slide the beam from the step before over a piece of pipe en than weld it to the handle.

Second you have to slide a same piece true the handle and then weld it to the frame.

You can find the dimensions in the file.

Step 5: Bottom Plate

Cut the MDF plate in a way it fits into the frame.

You can find the dimensions in the file.

Step 6: Pressing Plate

Cut the rest of the MDF so the plate can slide up and down the frame.

You can find the dimensions in the file.

Step 7: Side Plates

Edit the PVC sheet 30cm x 50cm x 12mm.

You're going to have to mill two strokes out as guideline's for the bearings later , we were able to use an automatic milling machine but it's possible to make it with a hand milling machine too.

You can find the dimensions in the file.

Step 8: L-Profiles

Attach the L-profiles 15cm x 8cm x 2mm with bolts and nuts through the pressing plate such as, if you set the handle level, the pressing plate and the rotating point are perpendicular.

Step 9: Guides

First you have to cut the Axis of steel ø8mm (±24cm) into 8 different pieces.

Second you have to thread the pieces until half with M8.

Then you press the pieces into the bearings en screw them on the L-Profiles 10cm x 10cm x 2mm with a M8 nut.

At last, position the L-profiles on the pressing plate and make sure that the bearings perfectly glide into the guides.

Otherwise the pressing won't be smooth.

Step 10: Sawblades

First you have to weld 3 nuts M8 spreaded on to the sawblade.

Second you have to take the PVC sheet 30cm x 30cm x 2mm align (see file) the sawblades onto it.

Then screw them together with bolts.

At last screw the PVC plate on to the pressing plate with M8 bolts and nuts.

You can find the dimensions in the file.

Step 11: Cardboard Guide

Edit the Polycarbonate 40cm x 30cm x 2mm to the right dimensions and attach on the bottom plate.

You can find the dimensions in the file.

Step 12: Rubber

Edit the Rubber andplace it into the bottom plate.

You can find the dimensions in the file.

Step 13: Clips

3D print the clips and attach them on the back of the frame.

These are necessary to make sure the carboard is secure.

The print file is in attachment.

Step 14: Locks

Aline the 2 parts of the lock on the side plate and pressing plate that if you pull the handle up they click in each other and the handle stays in position.

You can buy these locks in every homedepot store.

Step 15: Security Plate

Edit the rest of the Polycarbonate 40cm x 30cm x 2mm and attach to the side plates

You can find the dimensions in the file.

Step 16: Enjoy!

Now you can create a box from cardboard like you've never seen before!