Make a Jigsaw Stool (plywood)

Hello folks!! Interested in making a jigsaw stool?

Its fun putting together a jigsaw puzzle, isn't it? So let me show you how to cut out a puzzle on a single sheet of plywood and create a stool. Let's build a modular furniture which like a piece of puzzle, can be unravelled from the board and assembled to build a real stool. Does this not sound fascinating?

I had made this stool when I was doing an internship in an architecture firm. I loved this project, as I had to sketch, research, learn sketch up and the dreaded AutoCAD along the way. The most exciting part was watching my design get carved out by a machine. I am here to share this joy and give you a glimpse into the mesmerizing world of designers and architects. So that In future you can design your own furniture by following this guide.

So without further ado, let's begin.

• A computer
• Autocad software
• Fusion 360 or Sketch up
• Birch wood ply : 600mm x 900mm x 16mm
• A CNC Machine
• Wood glue : Fevicol
• Sand paper: 600, 800 and 1000 grade

The Aim

When working in an Architecture firm, it's very important to know the objective of making a certain product. If one doesn't have a valid reason to create it, one can not afford to waste time and resources on such a project.

• To Learn to work in a constraint.
• To learn about basic joinery.
• To work with CNC machine. (Computer Numerical Control)
• To learn Auto cad, Stool being the channel for this purpose.

The Goal

In design, constraints are helpful as they keep you on track and provide you a framework within which you can make something. My constraint in this project was the size of the plywood that I could use. This was to test my ingenuity and to ensure there was no wastage of any material.

• The challenge was to make a stool in 600mm x 900mm x 16mm board. (The CNC, which is used to make this stool, cannot work beyond an area of 600mm x 900mm)
• The constraint forced me to make a minimalistic design, that utilised most of the Birch wood ply.

• Sketch a stool that can be made with CNC.
• Figure out its joinery.
• Refer the time saver standards to learn proportions of stool.
• Draw plan, elevation and views of the stool in AutoCAD.
• Fit the parts of stool in a rectangle of 600 x 900mm.
• As it is going to get machine cut, keep a tolerance of 16 to 20 mm between each part.
• After drawing in AutoCAD, assemble the stool in SketchUp.
• Check in Coral Draw if the parts can be cut by the machine.
• Import AutoCAD file to CAM(computer Aided Manufacturing) program which will convert AutoCAD to G code which controls the CNC mill while it cuts the parts.
• Save the file in a pendrive and insert in machines port and you are ready to make a stool.

Before I began making the stool, I had to study existing stool designs to understand what's possible to make on the CNC machine. The CNC I was using was of 3 axis. So, the CNC - arm was limited to 'X' horizontal , 'Y' vertical and 'Z' to give depth.

Keep in mind also the floor size of the CNC. The CNC, which was used to make this stool, could'nt work beyond an area of 600mm x 900mm. So the maximum dimension of the Ply that I could use was decided by this constraint.

Newton said, 'If I have seen farther, it is by standing on the shoulders of giants'. This means, he advanced further on the foundation left behind by his predecessors. To learn from this wise man, there is no point reinventing the wheel, which is why the architects follow their holy bible, 'The Time Saver Standard'. This book has the measurements of commonly used objects. So that the ergonomics are taken care of and you need to just design the stool following the dimensions given in the book.

Once you have sketched the stool, the next step is to figure out how each part will join the other. Study different types of joinery to get a better idea.

• Draw the views of the stool in AutoCAD. Draw the front, side, top and section views.
• These views are drawn to determine the dimension of each part which would be placed on the plywood.

Note: In an architecture firm, all furniture drawings and building plans are drawn likewise to ease communication between the architect, the contractor and the builders.

• Sketch the parts of stool in AutoCAD.
• Sketch a rectangle having the dimensions of the plywood and draw the parts within that constraint.

You can derive the dimension of the parts from the plan (previous step)

• Fit the parts of stool in a rectangle of 600 x 900mm.
• As it is going to get machine cut, keep a tolerance of 16 to 20 mm between each part.

Fusion 360 and Sketch up are two 3D modelling softwares, that help in visualizing a 2D drawing in 3D. You can use either. I had to learn sketchup as the Architecture firm was using this software.

• After drawing in AutoCAD, assemble the stool in SketchUp.
• Check in Coral Draw if the parts can be cut by the machine.
• Import AutoCAD file to CAM (computer Aided Manufacturing) program which will convert AutoCAD to G code. G code controls the CNC mill while cutting the parts.
• Save the file in a pendrive and insert in machines port and you are ready to make a stool.

• Once the parts are cut, remove them out of the plywood. It wood look like image 1.
• Sand each part with 600, 800 and 1000 grade sandpaper.
• After each part is smooth enough, assemble the stool.
• Use wood glue to firmly fix the parts.

Caution: Be careful while sanding as ply splinters can easily lodge into your palm. Removing them is more of a pain than wearing a pair of gloves, so wear gloves and handle with care.

• To assemble, glue the different parts and watch your stool take shape.

This is the most exciting phase as your hard work comes to fruition.

• Once The stool is assembled let the stool dry for some time.

Note: Working with the constraint meant that I had to compromise a little with the height of the stool. I would have preferred the legs to be an inch or two longer.

Once you have assembled the stool, you can either keep it in your drawing room as a coffee table by placing a glass sheet on top or use it as a regular stool to sit on. It will provide adequate support, is light to carry and a comfortable seat to relax on. Hope this instructable helped you understand the design process and the steps to build a product.

If you find this Instructable helpful, please like this guide and share your thoughts and insights in the comment section. Thank you!!