Open Design for Wood Structures

Masterthesis by Felix Dannecker

”Open Design for Wood Structures” consists of a  series  of strategies to  enable  anyone,  using  low-cost fabrication machines,  tomanufacture modular  interlocking  wooden elements without acquiring advanced  crafting  or technological  expertise.  The proposedapproach relies on two complementary steps: A method  to generate  cutting guides and  templates and  manufactured them  with  low-cost FDM  3d printers.  These  allow accurate  manufacturing of timber  joinery  on conventional wood-working machines. A workflow for the  design and  fabrication of reversibly  assembled  modular  structures  composed of timber  elements  with custom  joinery. Due to the highprecision required  to fabricate  with timber  joinery, such structures are usually produced  by highly skilled craftsmen  or by using advanced CNC manufacturing processes . As an alternative, Felix proposes a method  to analyze a given joint,  and based on a selected wood-working machine,  define the  relative  placement  between  the  tool and  the  timber  element  for cutting the required  shape.   The  positions  are  then  encoded  in a 3d printed cutting template, which allows a user to precisely place a wooden part on a woodworking  machines, allowing precise fabrication without need for advanced  wood-working skills.  A first iteration of the method  relied on creating cuttingguides to be used on a table  saw.  A second iteration, further  reduced  the  need for large tooling,  by replacing  the table  saw with ahand-held  mill.

Thesis supervision: Andrea Rossi, Oliver Tessmann