The Unconventional Guide to Client Projects

The types of projects that we undertake at Makersmith are so varied that each one brings it’s own unique challenges; no routine work for us!  As a result we have to make sure that we learn as much as possible from each project and embed whatever we have learnt into the next.

An important part of this is time recording; it’s really easy to significantly underestimate the time taken to carry out a design or manufacturing task as we naturally tend to be optimistic when we envision a process.  If, having carried out the task, we know exactly how long it took, then we are in a much better position to not only plan the next project timescale more accurately but to give our clients the most effective quotations for work.

Our Unconventional Guide is based on one day’s time logging for a project for one of our design team:

7:45am Arrive at work, coffee, review schedule for the day. Update project planner to record completed work.  Check emails, check client emails into CRM system.  Fire up SolidWorks ready to review project CAD model

8:22am Take call from client with detail query as they are on the way to work. Reassure them that we have resolved the query and will confirm with them by email before the end of the day. Log the call in the CRM system

8:27am First task this morning: resolve the design of connections between steelwork and timber components, build detail in to the outline concept model until it is completely resolved.  Compare the solution with the the requirements of the detailed Project Specification it’s in line with that.  Review the detail to make sure there are no untested assumptions.  Double check the availability of special fixings they are normally a stock item.  Record this and the full specification in the project Bill of Materials.

Designer's Coffee10:35am Really stop for coffee…

10:46am Prepare for client meeting at 1pm for new project. It’s great to have such an amazing meeting venue the Old Kitchen at the Abbey enough to excite any prospective client; make sure the room booking is confirmed…

Set up paperwork, initial documents and detailed specification questionnaire to run through with client.  Make sure the computer Works!

11:33am Review key issues for new project and carry out research into alternative materials and suppliers.

12:07pm Lunch a short walk in the woods and back for…

12:48pm To the Old Kitchen to check the setup.

1:15pm SolidWorks modelMeet clients with colleagues. Chair meeting and lead through client requirements, detail specification issues, identify areas where we need more client information and where more research is needed. Conclude with summary of our respective actions and timescales to complete.  All done.

14:30pm Return to office and complete meeting notes for project file/audit trail and summarise on CRM system.

15:07pm Check in the workshop to see progress of another project and evaluate stiffness of the structure having done the design originally it’s good to see it in the flesh and to feel that it is just as designed.

15:22pm Back to detail project work.  This time taking detail computer data out from SolidWorks for use in manufacturing systems to create laser cut steel profiles.  Also take timberwork profile data for production.

16:02pm Use CNC tooling program to check the correct machining sequence for the timber.  Revise the design slightly in SolidWorks to optimise machining time and re-check the CNC programme. All fine.

17:16pm Review emails that have arrived during the day and allocate responses to future time slots.  Reply as necessary.

17:46pm Shut down the computer to go home. Leave through the workshop where the CNC machines are still running. Out into the evening air with the hazy view across to the hills and stumble over a flock of Quail that seem to be wandering around the car park and perching on the cars…

Another day at Makersmith…

Carving and Engraving

We have enjoyed CNC carving some three dimensional signs for a nearby theme park.  The level of sharp detail we can create is excellent and rivals hand carving  – especially as it’s more consistent.

Three dimensional engraving of thick Foamex
Three dimensional engraving of thick Foamex

These signs were made from high density plastic Foamex but this type of carving can be applied to timber as well as other plastics.  It’s possible to re-create intricate timber carving relatively easily and it’s particularly useful when creating multiple or batch parts.

What’s more exciting is that we can also CNC carve an infinite variety of textures in these materials too.

We created a sampler to show some different textures using a number of different tools so the only limit to the type of surface is your imagination.

See what else we can do here…

Engraved CNC texture sampler
Engraved CNC texture sampler

IMG_7082

Supporting Safe Working (Literally..!)

Pulsar Instruments Plc, founded nearly 50 years ago, is an established and well-respected manufacturer of noise measurement instruments. The devices are used exclusively by health and safety professionals to monitor industrial noise levels and to ensure that they remain legal.

Safeer Sign
The finished SafeEar Max sign

Makersmith were asked to manufacture structural framing to support Pulsar’s innovative SafeEar Max signs which can be wall or pole mounted in factories or worksites.

 

The front panel can be changed to provide hearing protection warnings or simply messages to encourage people to reduce noise.

We manufactured and assembled the frames from CNC cut plywood sections so that they would be both cost-effective and stable.

Using plywood in this way allowed us to make the frame elements self-aligning so improving accuracy and simplifying assembly.

Framing Components
Plywood framing components

 

The client was really pleased and gave us the following feedback:

“Thanks for the wooden frames, they’ve been a great success for this project, providing suitable stiffness for the environments they’ll be used in plus the flexibility for the customer to mount them in various locations.”

It pay to think “outside the box” for structural products; see what we can do then talk to us and we can help with solutions in timber, steel and a wide range of other materials.

 

Assembled frames in a stack
Assembled plywood structural frames

It’s been great to work with Pulsar Instruments who have a strong presence in the UK and sell products to over 40 countries around the world via an extensive distribution network. All Pulsar Instruments’ products are manufactured in the UK and are above all affordable, robust, easy to use, yet accurate.

 

You can find out more about Pulsar at www.pulsarinstruments.com or you can email the team at sales@pulsarinstruments.com or ring 01723 518011…

New Kitchen? Make it your way…

Kitchen doors get a lot use and wear and the most common melamine or foil faced doors are hard to repair once they are damaged and the surface layer is broken.  Using birch plywood is a simple and cost effective way to construct doors that both look good and are easily repairable & refinishable – and, as in this case, have integral handles too…

We were approached by a client in London who was looking for a range of plywood doors for their new kitchen. Starting with their initial list we prepared a door schedule and  provided 3D visuals of typical doors, prepared using our SolidWorks 3D design software.

Handle Drawing Detail
Detail of the integral handle to be positioned in the centre of one edge of each door
Close up of Handle
Integral handle machined into the plywood

 

We also supplied a detail of the integral handle that our clients particularly required:

Once these details were approved we manufactured a single door as a sample and sent it off to our client for approval before manufacturing the whole batch.

Our whole communication process was aimed at ensuring that our client was happy at every stage, both with design and materials.

Door handle cose-up
Door handle machined into the edge of the plywood door panel
Completed door panels
An array of completed door panels in a range of sizes

After sample approval we then manufactured the full batch of panels, coated them with satin finished wood wax and shipped them off to our client for them to install.

 

 

 

 

 

It’s great when we get spontaneous feedback from our clients; in this case we were really pleased when our clients emailed to say:

“Just a quick note to say we are delighted with the door panels, thank you so much for such a wonderful product and exemplary customer service. … they look smashing. We’ve passed your details to our architect who is very impressed.”

All sort of door shapes and profiles are possible so get in touch to see how we can make just what you need…

 

 

Retro Cool

Do you remember the very first video games? The tennis game? The “ball” that bounced from one side of the screen to the other and you had to catch it by sliding paddles up and down at the sides of the screen? Well, if you do you are probably really very old and the games industry has changed just a little since then.

Picture of the console enclosure
The SolidWorks 3D model of the enclosure assembly

 

Jack Barber was inspired to replicate this tennis game using a Raspberry PI as a training exercise. He was looking for an enclosure to house the game that would reflect the retro feel of the original.  Having talked to us we designed a sloping plywood enclosure with a white Perspex faceplate that was suitable simple, retro and durable.

We used SolidWorks to prepare the 3D design which then allowed us to export all the part details for machining on our in-house CNC Router and Laser cutter.

The faceplate was laser cut from white Perspex and the casing parts from birch plywood.

Perspex faceplate
The laser cut Perspex faceplate

 

We then assembled the unit, adding threaded inserts to enable the back panel to be easily removed. The whole case was given a clear wood wax finish and the Perspex panel bonded in place.

All of which goes to show that for one-off or small batch quantities you don’t need to get a plastic enclosure, it’s possible to make something much more tactile and creative.

Result – a housing that met the brief perfectly and has enabled Jack to build the tennis game; now to make some more…

Finished product
The finished enclosure

 

And don’t forget – if you need something making – however retro or unusual, just get in touch with us!

 

 

 

 

 

You can find out more about Jack Barber here.

Boxing Clever…

It’s great when we can solve problems for our clients! This week’s story is about a client who was looking for a small initial batch of re-usable shipping boxes that were to be in two sizes (one up to 1m long) and relatively low cost.

Our solution was to design the boxes to be made from 4mm thick black Correx (fluted plastic sheet).

Correx Box with open lid
The SolidWorks model

Using SolidWorks 3D software we were able to model the boxes to include all the connection and alignment details and then easily produce the unfolded box details.  These were then cut and engraved on our CNC router to produce all the parts needed – in this case the main body and left and right-hand ends.

 

CNC Router Layout
CNC Router tool path layout for main box body

We then assembled the boxes by folding along marked lines and bonding the components in place with specialist adhesive.

 

The boxes worked first time and our client was really pleased; a great example of how we can creatively solve design problems and give you the products that you need.

Get in touch to see how we can make what you need – whatever it is!

Completed Box
One of the finished boxes – it looks as intended – identical to the 3D design model