Waag Society Fablab Amsterdam

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In this project we aim to cast a box consisting of 2 materials: a hard inside to keep electronics in place, and a soft outside to make it shock proof.

First we will cast the epoxy inside of the box, using 2 molds. Then we cast an extra layer of vitaflex rubber on top for the soft outside. For the whole process the laser cutter and the shopbot are needed, and the toolset for moulding and casting.The process consists of the following steps:

1. design of the moulds in Rhino: one mould for the core; one for the epoxy shape; one for the vitaflex layer

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I applied the press-fit joinery technique to costruct the box. Once I figuered out the general measurements of the box I adjusted the pattern of edges to click together. The first thing to consider when designing this pattern is the thickness of the material. In this case I used 6mm mdf, so the pattern has to match that. The other important thing to consider is whether the joinery pattern defines the inner or out the outter periphery of the box design. It doesn't matter which of the two options you chose as long as you stay consistent.

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Inspired by a hand-made cigarette box that I found once in an antique market, I wanted to recreate this contraption using the fablab facilities.

The problem (and part of the charm of this object) is that there is no way to open this box without breaking it. It simply presents cigarettes each time one attempts to open it by sliding the top surface up and down. Its mechanism remains enclosed and mysterious, resisting interpretation and reproduction.

In order to figure out its inner geometry and the steps to assemble it, I started by creating a carton maquette.

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This is a lamp i made as a Christmas present.

1. modeled in Rhino (mac version): important, thickness material is determines the design and circumrefernce of top. crucial to draw parts and assemble virtually before you make it.

2. Machined on the Shopbot on 9mm plywood: important; using tabs was crucial, otherwise parts went flying throught the room: tabs rock, thanks alex. My cut file had pieces that were too close to eachother, this caused some loud and potentially dangerous moment: Better to waste some wood then end up with it in you abdomen.

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Fab Foos is a open source Table Soccer Game, featuring 2 web cams, audio response, electronic counter system and vga out.

The goal was to built the entire table using the machines of the Fablab.
We constructed it in such a way that all digital production methods are used and all fablab machines.

There are a view parts we bought in, sinds it didnt make sence to me to produce them ourselves, or it was to expensive.

The parts we bought in were:

- 4 rods
- 16 barrings
- 8 springs
- 8 rubber  stops