After completing a first mockup of one of the ten partition walls in the project, we realized staying consistent with dado cuts (slots) in the wooden members composing the walls was difficult. With the recent addition of a three-axis CNC (essentially a robot for carving wood) in the shop, we decided to take a digital approach in fabricating these members. Consistent depth and aligned slots will ensure final assembly of the layered walls proceeds smoothly.
For the second mockup, we needed to test the reliability and constraints of CNC fabrication. After generating an initial digital model imagining how the boards might be arranged and cut on the machine, we consulted the Cigar Factory’s resident expert, Matt. On Monday he walked us through the process of converting 3D geometry into something the CNC could read as fabrication information. The machine would cut the dados and pre-drill for perfect alignment of screws securing the layers together.
Yesterday we went down to the shop with Matt and ran the first cut file. Unfortunately, we discovered the suction of the working surface (which is like a reverse air hockey table) was not strong enough to overcome the friction of the spinning carving bit, shuffling the boards askew from one another and misaligning the dados.
After putting our heads together, we think we have a potential solution: create a giant clamp. We will take a 2x member and cut a slight convex curve into the bottom. Then, we will attach open threads along the alignment boards ringing the perimeter of the CNC’s work surface by which to bolt down the convex “clamp” across the slats to be cut. Today, we find out if this idea works!