In this instance, we used Solidworks to model and render the product, allowing us to export the needed patterns for client review and approval.

Accurate cuts are essential for quality joints.

Once the PLA sheet is made, cut it into the five pieces needed for the product. The precision of the cuts depends on the tool used. We used an endless saw, resulting in rough cuts, which we then refined with a CNC router.

First, transfer all markings to the pieces and begin cutting. It is crucial to cut slightly less than needed initially, then test the joint. Trim more as required and repeat until achieving a perfect fit. Additionally, we used a file to smooth edges and make minor dimensional adjustments.

Once fit properly, use a heat gun and spatula to weld joints, ensuring the tray remains sturdy.

Contextualize and Provide Details

More photos available here.