Frame Construction Set

Introduction

There are different options for the D3D frame that have been tested:

1. CNC cut from flat - then welded or epoxied - works best with welding, second best with epoxy (more difficult)
2. Epoxied from flat bar
3. PVC - appears to work

Frame from Flats

BOM

• 30' of 1/8"x1" flats, $13.50 from Sweiger Shop
• Self mixing epoxy, 3 tubes at $4 each, $13 total [1]

Procedure

• Using 1/8" by 1" flats, here is how you make a frame:

1. Cut flats to 12"
2. Clean and grind edges to be glued
3. Assemble frame over a template
4. Fix frame to another metal template with magnetic attachment
5. Glue ends with self-mixing epoxy on both sides

CNC Cut File for Starting from Sheet Steel

3-Nested

4-Nested

Cut Request Template

(can use oxyfuel, plasma, laser, or waterjet)

Hello,

Please provide a quote and turnaround time for CNC cutting for the attached file, cut from 4'x8' sheet, 11 gauge.

I need 6 of those nested sets (as shown in the file), which take a total of 32" of a 96" long sheet. I have more notes on this cut job at D3D Frame (below).

Thanks, Marcin

Download

• Download Layout on a 4'x8' sheet of steel: File:D3dframe layout.dxf
• Download Single nested frame piece: File:D3dframe.dxf

Notes:

• Frame pieces are square:

• 16" for outer square, 2" edge width
• 12" for outer square, 2" edge width
• 8" for outer square, 1.5" edge width
• Save the inner square. It will be used for mounting plates.

• if sheet is not exaclty 4'x8', an edge must be drawn around the frame so that every outer nested piece is exactly 16" on the side.
• 3 nested pieces can make 3 frames (each frame is made of 6 pieces

Online Viewer

View online by uploading the above file - http://dwgfastview.gstarcad.net/Flash/choose.html

Cost Estimates for Various Locations and Quantities

Single

• Chile-
• Maine -
• Texas Frame Cutting Quote - $157
• USA Missouri - Seaman and Schuske, St. Joseph Missouri - job cost $150 for cutting of the nested set above.

Multiple

• 6 sets of frames, 10 ga, Seaman and Schuske, St. Joe, Missouri, USA - $575

Development Document

edit

Links

• Critical Path for D3D 2016 - edit