working with furniture makers

Working with furniture makers

Posted Posted in Designers, Furniture, How to, Wood

Hugh Parsons Design is a furniture maker based in Newbattle. Hugh has created a striking maple, cherry and fumed oak mirror with a celtic pattern using traditional marquetry techniques.

He asked LaserFlair if we could engrave a recessed triangle pattern on the mirror frames and also laser cut fumed oak veneer into triangles of three sizes. The engraving creates enough depth for the fumed oak triangles to sit into so that they sit slightly proud of the frame. Once fitted, Hugh sands the frames so that the triangles are flush with the surface of the frame.

Hugh and I spent a good half day doing tests to make sure that everything would fit together properly!

Testing

First, we test engraved some triangles on frame offcuts. After a few tests, we selected engraving power settings to achieve the right depth for the oak veneer to fit so that it was neither too shallow nor too deep in relation to the mirror surface.

Engraving

Then we set up the mirror on a jig so that the laser was aligned as closely as possible to the frame while the triangular pattern was engraved. The large triangles in the top right and bottom left corners of the mirror point right into those corners. Human eyes can detect an error or 1mm or more which would detract from the effect. We use a jig to get as close as possible to perfection as doing it by eye just isn’t accurate enough.

Cutting the veneer

Finally, we needed to make sure that the fumed oak triangles would fit the engraved areas properly. I cut some samples and Hugh tested them for fit, knowing what he required for best results. We had to tweak the sizes a bit to get them right. The veneer was quite hard to cut as it comes in quite tight rolls. We had to weigh the strips down to keep them flat during production to make sure they ended up with the right sizes.

Hugh finishes off the mirrors by cutting grooves at 45 degrees to the frames. He coloured them to match the triangles, and the effect is striking and beautiful. We’re so proud to help craftsmen to create such beautiful pieces. Hugh exibited his Celtic Mirrors at the SFMA exhibition at the Royal Botanic Garden Edinburgh in 2016. He also sells them on his website.

how to create a giant jigsaw puzzle

How to create a giant jigsaw puzzle

Posted Posted in Artwork, Designers, Exhibitions, How to, Wood

FifeX designs, creates and installs bespoke interactive products, exhibitions and educational resources. They’re based nearby in Tayport. Ken Boyd approached us to help them produce two A2 sized jigsaw puzzles for their customer, REME Museum of Technology. REME wanted to replace two puzzles that were worn out as they had been so well used by visitors.

The museum had two images that they wanted to make into jigsaws. We thought long and hard about the best materials to use and how to cut the pieces accurately, and came up with a plan.

Choosing a material

Firstly, we had to select a material to make the jigsaws from. We settled on 6mm birch plywood because it laser cuts well and wood is a lovely, chunky material to handle. Being pale in colour, the pictures would show up clearly. Also, the wood grain would be visible through the print, a lovely feature. And plywood is robust, chunky and lightweight, very important considerations when the product is designed with younger visitors in mind.

Creating the jigsaw

Once the customer had chosen the material, LaserFlair cut two A2 sized shapes from 6mm plywood and sent them to the printer. They applied the pictures and returned the panels to LaserFlair for cutting into jigsaw pieces.

FifeX found a piece of software for designing jigsaw piece layouts and shapes. It created vector lines that the laser can follow to cut the lines between the pieces. We could select how many pieces we wanted in the x and y axes, and choose regularly or irregularly shaped pieces. We decided on 20 pieces to make each piece the size that the customer wanted, and selected an irregular cutting pattern for more interest. Then we laser cut the puzzle.

The whole process was a great success. This picture shows one of the jigsaws sitting on the laser bed after cutting.

plywood pitfalls

Plywood pitfalls

Posted 1 CommentPosted in Artwork, Designers, How to, Wood

You’d assume that 3mm plywood is 3mm thick, wouldn’t you?

Wrong! With plywood, thicknesses are nominal, not actual. This is because plywood is made up of different layers glued together. 3mm usually has 3 layers, and the result is an actual thickness of 3.2-3.3mm. 4mm ply has another layer, and is usually 3.8mm thick.

Potential design disasters

This can create a whole worlds of pain for designers and manufacturers if they want to create products made up of pieces that slot into each other and require a good fit.

If you assume a thickness of 3mm and you design 3mm slots in artwork and then try to fit 3.3mm thick wood in the slot, it’s not going to happen. Or if 4mm ply were used, 3.8mm parts would be too loose.

Case study

Imagine making 300 reindeer kits for Christmas, sending the artwork to a maker, and getting back parts that don’t fit?

This could have happened to one of our earliest customers, but we made a prototype, realised the problem and fed it back to the customer. They tweaked the artwork before we performed the production run. This simple check saved our customer –  and us too –  a lot of time, money and heartache.

Always check that your designer and maker are speaking to each other to avoid disasters like this.