The X-tool is a neat substitute for seating arrangements at social gatherings. Light weight makes it easy to move and re-arrange. Combine the Xtools and create a large table like structure for playing board games etc. The structure has been planned in such a way it creates minimum wastage and can been carved out from a single plank of wood. The three components have been ergonomically designed for 95 percentile.

What else?

No joineries
Easy assembly
Precise fix

Dimension

Width - 398 mm

Height - 437 mm

This Xtool can be made using left over peices of mdf or Plywood as the dimension are 450 * 350 mm only, and transformed into a classy stool for your home spaces.

Step 1: Materials and Tools

List of materials

18mm plywood (you can take teak wood also)
5mm MDF
Sandpaper
Oil paints
Plastic foot pegs/5mm acrylic sheet
Wood polish

List of tools

Router with flush trim bit
Drill
Laser cutting machine
Clamp

IMPORTANT: measure the thickness of your plywood.This is really important to take note because the design has locking parts and we need to accommodate for a thicker material. The slots which I've made are according to 18mm thickness. You can modify the files according to your material thickness.

Step 2: Fusion File

I used Fusion 360 to design the stool as I'm familiar with it. You can Edit the file in any version you wish.

You can download the Fusion file and edit the design.

I have given separate file for component that will run on laser cutting machine to make base for router machine. You can slightly increase the size of the slit by 2mm on all three component because router blade leaves 1mm difference while cutting. So for easy fixing edit it slightly.

For foot pegs either stick ready made plastic pegs or cut rectangular slab piece from acrylic sheet using laser cut machine, stick with any super glue you wish. Use file attached.

Important

If you're making it on same thickness of material, use .dxf file directly to the laser cut machine.

Step 3: Cutting Base for Router

Using .dwg files of the component, cut 5mm thick MDF sheet. these parts will be used as a base for router machine. You can also draw 1:1 scale size on plywood and clamp straight piece of wood for router to work. Cutting base layout with laser machine will make the task easier.

Laser machine setting

power - 90-100
Speed - 5

Step 4: Cutting Final Pieces With Router Machine

Arrange all three parts as shown in the picture and cut plywood accordingly. Also leave some bleeding space. Clamp laser cut piece with plywood (edge to edge) tightly. I used Bosch router with flush trim bit with the speed between 5-4. Go slowly and carefully while using router. Wear all safety gears to protect yourself.

For top

To make a hole inside the surface of the material, make a hole using drill wide enough for router bit to pass through. Start the router and make the cut slowly.

Important :

Router does not give 90 degree edge, for that Use the T Bone slots in you drawing files and cut accordingly. If you are making it with CNC machine, you have to make T bone slots and give commands to the machine. I want to avoid T bone slots, so I filled the edges to 90 degree very precisely with sander (you can use sand paper of grade 80)

Step 5: Sanding the Components

After cutting all three component its time to sand the edges and surfaces with hand sander. I used Bosch 40 and 320 grade circular disc paper for sanding. It gives you very smooth surface. I removed topmost layer of the plywood to give it wooden finish. You can simply sand the surface or play around as you wish. Refer photo for the surface clarity.

You can use sandpaper of grade 80. For smooth surface gradually increase the grade from 80 to 1000, this will give very smooth finish to the surface.

Step 6: Paint Legs and the Top

I applied wood primer on the legs and top support and kept them to dry for almost 6-8 hours in a close room. After the primer was dry I applied a layer of oil based paint(grey for legs and gloss yellow for top). I left the legs and top to dry for 5-6 hours. And after it dried I applied another layer of oil paint. After paint job I sticked plastic foot pegs with any super glue. I used Anabond cyanoacrylate 555 M.

Painting is optional if you are satisfied with wooden finish. In this case apply wood polish to the surface.

Step 7: Assemble Legs and the Top

Legs fit perpendicular to each other into the slits. Use mallet to fix them properly. Align top to the X mark and mallet it gently into the groove and your stool is assembled.

Step 8: You Are Done

And your Stool is ready !

All questions, suggestions are welcome !

Step 9: CNC File

For those planning to do this stool with CNC. I have attached file that I used with CNC (.art), and in case this file doesn't work just upload the png,dwg,dxf file in CNC software you're using and trace the outline, as it is a simple 2D cut. Bit size used for cnc is 5 mm.

After CNC, Slits will be tight to fix. Don't worry, sand all the surfaces of the legs and the top and slits will become wider and smooth.

Repeat same steps for finishing the stool.