Forgive me blog, it has been over a week since my last posting. A lot has been happening. Not all of it great, but I am moving forward. I had hit a snag as far as the mold making part of the light creation was concerned. Using the rapid prototype machine would have produced a model that would have cost well over $500. In the ‘real world’ the cost would be 4 times that. Still, Plan B has been put into effect. Plan B is to use MCAD’s CNC router to make the model instead. The problem with this is, (1) I have to assemble the pieces together (this will fall under the heading of ‘finishing work’) and (2) the most ideal material for the job is MDF. Typical MDF is not eco-friendly. There does exist an eco-friendly version on the market and I do have some samples coming (I can’t find a distributor in the Twin Cities) from a place called http://www.sierrapine.com. They have some really cool green materials. I’d like to get my hands on their MDF that can be powder coated. Some day…
Anyway, the mold had to be redesigned and cut into pieces that were the same thickness as the MDF (3/4″). The file looks like this:

These pieces then are stacked and glued together. Viola, a mold! The same process will be completed for the other (postive) part of the mold.
I thought that the light would be the easiest part of the process, but so far this is proving to not be the case. I am hoping that this will come together in the next 2 weeks.

I have finalized my chair design.

To give the chair more character and to make a material connection with the table, I have added plastic components from the left over ecoresin of the table to the chair. Handles in both arms as well as one at the front edge of the seat will be emphasized with inlayed ecoresin. They are both decorative and bring attention to the places that have been designed for grabbing (be sure to click on the image to see it in a larger scale).

I made a quarter scale model with the rapid prototype machine ($89). I am glad that I did this as it shows that the connections will work where I have them and that the seat will flip up and stop before hitting the backrest but at an angle where it can be carried and not flop around.

My man James at North Star Surfaces has secured some sheets of Biofiber Wheat for me at a nice discount ($90 for two sheets that are 3′x 4′). Normally one 4′ x 8′ sheet cost twice that. Thanks James! I had wanted to use Plyboo for the drawer of my desk but he had no left over material in the thickness that I want. A new sheet of 1/4″ Plyboo is $250. Too much especially when I need to spend money on labor to have the drawer made. I am going to look into FSC certified wood instead.

The table legs are being made by David Hill. I expect it to be done any time now. I hope to be able to take a few pictures of his shop. It is definitely worth a picture or two.

BTW- if you are getting this in e-mail form, know that there is a link to the blog itself at the bottom of the email.
More to come.

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