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Manufacturing Plan. Methods for building in the Innovation Space with limited power tools and skill sets . Mortise and tenon joint (top right picture ‘A’) Tenon – rectangular protrusion from the male joint Mortise – female joint with a square opening - PowerPoint PPT Presentation
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Innovation Space
Manufacturing Plan
Basic Wood Working• Cost: $50• Tools:Ryobi Japanese hand saw, marking knife, layout square, sandpaper, clamp, chisels, brace and bit, drill bits, wooden mallet• Uses simple hand tools and a basic power jigsaw to cut female grooves and male connectors into wood for mortise and tenon, dovetail,
dado and dowel joints
PVC Connections• Cost: $10-15 for pipes, $1-3 for connectors• Tools: PVC cutter, brace and bit• Uses pvc pipe, pre-made pvc connectors and simple hand tools to assemble pvc pipes
Bamboo Joinery• Cost: $20 for tools, $3 for rope • Tools: hand saw, hammer, file• Uses simple tools and rope to create bamboo joints
Universal Joint• Cost: $20 for tools, $5 for sheet metal• Tools: metal sheers, sheet metal punches, hammer• Uses sheet metal working tools to hand mold a connector that can be used to connect things
Structures• Metal to Wood –Bracing and trusses• Strawbale—Pin Joints• Mud Bricks
Odds and Ends Joints• C-Clamps• Tie-Wraps
How We Build
Methods for building in the Innovation Space with limited
power tools and skill sets
Basic Wood Working• Cost: $50• Tools:Ryobi Japanese hand saw, marking knife, layout square, sandpaper, clamp,
chisels, brace and bit, drill bits, wooden mallet, block plane, waterstone• Uses simple handtools and a basic power jigsaw to cut female grooves and male
connectors into wood for mortise and tenon, dovetail, dado and dowel joints
Basic Wood Working• Pros: wood is locally available, very sturdy structures, easy
to cut• Cons: requires a lot of skill for certain joints, time
consuming3. Mortise and tenon joint (top right picture ‘A’)
Tenon – rectangular protrusion from the male jointMortise – female joint with a square opening
• Measure and mark the tenon; use the saw and chisel to cut
• On the female joint, measure and mark where the mortise will be
• With the largest drill bit, drill through the center of the mortise square and use a chisel to square the rest of the piece
• Fit the tenon in the mortise; drill a hole for the dowel on the protruding portion of the tenon
• Hammer the dowel the hole to secure the tenon in place
Basic Wood Working• Pros: wood is locally available, very sturdy structures, easy
to cut• Cons: requires a lot of skill for certain joints, time
consuming
3. Sliding Dovetail joint (top right picture ‘B’)
• Mark and measure the dovetail; a taper of 3-5 degrees is recommended
• Cute the dovetail and sand it until the edges are rounded and smooth
• To cute the dovetail groove, clamp the dovetail to the female joining piece and use it as a guide for the saw; cut
• Chisel the groove and sand until the dovetail fits securely
Basic Wood Working• Pros: wood is locally available, very sturdy structures, easy
to cut• Cons: requires a lot of skill for certain joints, time
consuming
1. Dado Joint (top right picture ‘C’)
• Measure and draw the groove cut length wise on the mating piece
• Cut each side of the groove ¼- 1/2 inch down
• Use a hammer and chissel to remove the wood for the groove
• Hammer the joining piece in place
Basic Wood Working• Pros: wood is locally available, very sturdy structures, easy
to cut• Cons: requires a lot of skill for certain joints, time
consuming
2. Dowel Joint (top right picture ‘D’)
• Measure and draw the spacing for the dowels on both pieces that are to be joined
• Drill half the length of the dowel down on each side
• Hammer the dowel into the holes on one piece • Match up with the joining parts holes, hammer in
place
PVC Connections• Cost: $10-15 for pipes, $1-3 for connectors• Tools: PVC cutter, brace and bit• Uses pvc pipe, pre-made pvc connectors and simple hand
tools to assemble pvc pipes
PVC Connections-Pros: initial low cost, light weight-Cons: not as durable as clay piping
1. The first step is to apply the primer to the fitting and pipe ends. The PVC Primer will soften and prepare the PVC Fitting or PVC pipe length for the cement that will be used when connecting.
PVC Connections-Pros: initial low cost, light weight-Cons: not as durable as clay piping
2. Next, choosing the cement may be the most important step in the process. Before applying the cement, you need to stir it well.
PVC Connections-Pros: initial low cost, light weight-Cons: not as durable as clay piping
2. After stirring, liberally apply it to both the pipe end and fitting socket. Add one more layer of cement to the pipe end, and then quickly assemble the fitting and pipe, ensuring a full and complete connection. Finally, wipe away the excess and let it dry
Bamboo Joinery• Cost: $20 for tools, $3 for rope • Tools: hand saw, hammer, file• Uses simple tools and rope to create bamboo joints
Bamboo Joinery: How To Basics• Pros: environmentally benign, sustainable, available locally, durable,
seismic resistant, easy to cut
• Cons: circumference variations makes joining difficult, no standard in universal joinery that is strong and affordable
1. Identify nodes – thick rings; these are needed for both ends of the joints or else the bamboo will splinter
bamboo joint node
Bamboo Joinery: How To Basics• Pros: environmentally benign, sustainable, available locally, durable,
seismic resistant, easy to cut
• Cons: circumference variations makes joining difficult, no standard in universal joinery that is strong and affordable
2. Similar to tube fitting (this bicycle frames), bamboo joint cuts have a male cut that fits into a female groove on the connecting piece
bamboo male cuts
Bamboo Joinery: How To Basics• Pros: environmentally benign, sustainable, available locally, durable,
seismic resistant, easy to cut
• Cons: circumference variations makes joining difficult, no standard in universal joinery that is strong and affordable
3. Cord or a dowel system (above left inset) can be used to secure the joint; wood nails will splinter the bamboo
Securing a bamboo joint
Universal Joint• Cost: $20 for tools, $5 for sheet metal• Tools: sheet metal shears, sheet metal punches, hammer• Uses sheet metal working tools to hand mold a connector that can
be used to connect things
NCIIA Cameroon Project Leslie Speer, San Jose University
"Reverse Engineering Bicycles to Develop New Businesses, Products and Increased Income for the Metalworking and Agriculture Industries in Lebialem (Cameroon)".
Universal Joint• Cost: $20 for tools, $5 for sheet metal• Tools: sheet metal shears, sheet metal punches, hammer• Uses sheet metal working tools to hand mold a connector that can
be used to connect things
1. Cut shapes out of sheet metal with metal sheers and punches (drawings can be found at http://cameroonprojectnciia.blogspot.com/ )
2. Hammer sheet metal to shape of connector
How We Connect
Methods and options for connecting similar materials,
mixed materials and hardware to projects in the Innovation
Space
Simple Structureso Mud bricks
shaped with wooden molds
o Dries in the Sun
o Clay+Straw+Water (simple materials)
Straw Bale
Sand and cement mixture
Straw and soil mortar
Straw bale Connection
Attach around secured pole
Blocks Pinned together
Woodworking: Pegs
Uses: 1. Furniture2. Vehicles3. Small
Structures
Metal Joints: TrussesMetal->Wood connections
Simple Mechanisms: Materials to Material
C-Clamp
Tie-Wrap
“Usables”: Materials to HardwareCasters Bolt and Lock Nut
Casters have four pre-drilled holes around it’s top support. They can easily attach to a flat surface using bolts and nuts.
Non-swivel wheels can attach using a bolt, spacer and lock nut assembly.
“Usables”: Materials to HardwareSurface Mount Hinge Mortise Mount Hinge
Attached to the door or frame; uses screws to secure
Mounted into recessed cutouts (mortises) on door's edge; uses screws to attach
“Usables”: Materials to HardwareEyebolts to Hooks Eyelbolt to Rope
An eye bolt screw could provide an easy connection to a carabineer style hook for a removable item, such as a bag that fits into a cart or to secure an item onto a cart
A simple way to secure items on a cart would be to attach an eye bolt to the frame of the cart in appropriate locations and use rope to secure it in place