Delta Stool

thingiverse

I design my cantilevered CNC-cut bar stool using a half sheet of 18mm ply, secured only with glue and doweled connections without metal fastenings. This structure is extremely strong, as it flexes rather than breaks under weight. Here's how I come up with the design: First, I measure existing stools to get precise dimensions, making sure to find the ideal seat-to-feet height for maximum comfort and a comfortable spot for placing your behind, supported by sufficient width. Next, I create a rough layout in SketchUp, working with different plywood sheet sizes - typically 4x4 or 8x4 feet - to maximize material utilization and optimize cutting layouts. I pay attention to features like mirrored faces so I can select the best side for each end piece. Refining the design is essential; I use SketchUp's powerful 3D assembly capabilities to achieve a flawless result, often returning to this software due to its user-friendliness and versatility when dealing with flat wood planks. No need for advanced CAD tools or sophisticated modeling; basic primitives get the job done. Only after refining the model do I send it to the machine for a test cut. And to truly assess the strength of my design, I ask friends to come and put their weight on the stool, providing a comprehensive stress test. **Step-by-Step Assembly** To create this sturdy cantilevered CNC-cut bar stool, follow these easy-to-follow instructions: Begin with 1/2 sheet of 18mm plywood and 6 hardwood dowels, measuring 270mm each. For a smoother finishing process, consider hand-finishining your plywood before cutting it. Start by placing one long piece on a flat surface; attach all dowel pieces using glue and doweling tools. To secure stability, place spacers, alternate between top and bottom layers, and apply glue to meeting faces. Use dowels to hold the frame in place, complete with clamping until glue is dry. Alternatively, pair up top and bottom layers along with their respective spacers before doing final assembly after the adhesive has hardened. Make sure that face joins and central dowels get proper bonding; these areas will bear the weight of stress. A successful bar stool hinges on solidly secured face joints at its base. To ensure durability, never scrimp on glue quality or quantity. I use premium-quality Titebond II glue - effective for cleaning up excess glue without damaging the surface during clamping. Add a smooth edge finish with a roundover router bit; then sand and seal with oil and varnish coatings. Felt pads are used on bottom surfaces to prevent damage. Using plywood for bar stools offers versatility; consider Meranti as your material of choice, thanks to its attractive colors and clear wood grain pattern - though Baltic Birch or Pine work just fine too. Steer clear from MDF; it is not only heavier than standard plywood but will chip quickly. In my opinion, its potential long-term structural integrity isn't impressive either. Incorporate dowels for additional support for your furniture pieces. Custom designs can include custom upholstered cushions, leather inserts - just reach out and I'll provide the necessary details. When sold in sets of 4, these pieces typically retail between $1600-2000 depending on finish applied. Businesses seeking to commercially reproduce this product can do so; for licensing, contact me at a fair cost.