Intolerance. Well, that is more or less what happens when you design interlocking parts that require decent tolerances, and the material scraps used in fabrication all come from different batches. I decided to make some flat pack fruit bowls to use up some of my plywood offcuts, but the first bowl was to be made out of red tint acrylic for a ruby wedding anniversary present. Acrylic is definitely not the ideal choice for something that is a combination of a) delicate, b) has lots of interlocking joints, c) will be handled a lot. However, in this case it was more about aesthetics because the bowl was to be an exo-skeleton for a clear glass bowl. The main design challenge was making the lasecut bowl fit precisely over the contours of the glass bowl. I made the initial prototypes from corrugated card to test out whether my idea and contouring was going to work. Once the acrylic design was finalised, I tweaked the form for a plywood version. The files for the latter can be downloaded for free from my Ponoko Personal Factory showroom. These customised if required and lasercut.
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