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Home > creating/designing a flat pack chair using fusion 360 and a laser cutter

creating/designing a flat pack chair using fusion 360 and a laser cutter

Define the chair concept and purpose.

Research existing flat pack chair designs for inspiration.

Sketch initial design ideas on paper or digitally.

Determine dimensions based on ergonomic standards and material constraints.

Open Fusion 360 and create a new project.

Set the units of measurement (mm or inches) based on material.

Create a new sketch on the appropriate plane for the chair base.

Model the chair components (seat, backrest, legs, etc.) using the sketch tools.

Use the extrusion tool to create 3D shapes from sketches.

Design interlocking joints or tabs for easy assembly.

Consider adding reinforcements to parts that will bear weight.

Flatten the 3D components into 2D shapes suitable for laser cutting.

Organize parts to optimize material usage and minimize waste.

Ensure that all pieces fit within the dimensions of the laser cutter bed.

Choose suitable materials (e.g., plywood, acrylic) for the chair.

Check the thickness of the material and adjust the design accordingly.

Verify that the chosen material is compatible with laser cutting.

Export the 2D designs as SVG or DXF files for laser cutting.

Create a layout for the laser cutter, arranging pieces efficiently on the material.

Set appropriate cutting and engraving settings in the laser cutter software.

Write clear assembly instructions based on the design.

Create diagrams or illustrations to accompany the instructions.

Test the assembly process with a prototype to identify potential issues.

Build a prototype using the laser-cut parts.

Test the chair for stability, comfort, and durability.

Gather feedback and make necessary adjustments to the design.

Finalize the design based on feedback and testing.

Prepare final files for laser cutting, ensuring all components are ready.

Document the design process and create a portfolio or presentation if needed.

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