The first part of prototyping with blue foam was to create the correct base to fit all the pieces on [see below]
Using Copydex glue, I created the base piece, slightly larger than needed, at 1050x600x200mm.
I clamped the edges and put a heavy weight on top and let it dry for 24 hours to prevent further bowing. The next stage is to get it on the CNC Router.
As my cork was not only expensive, but in a specific supply, as well as the CNC router being a new machine to the university where its capabilities had not been tested to the full, I decided to do another prototype, this time of my final design, but out of blue prototyping foam. My chair was a mammoth job as it was very sculptural and organic, and many different factors had to be considered including the tooling and overall scale. To first manage the intricacy of the design, we designed to make this prototype to a half-size scale. This would mean less time cutting and a quicker result of the feasibility of my design. Figure 39 shows the CAD model of the 4 quarters of my chair to be cut on one piece of blue foam (1000mm x 600mm x 125mm).
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