Cnc Furniture

============================================================ PHASE 1: STRUCTURAL ANALYSIS

Step 1.1 -- Object Classification

Classify the object by structural type:

• Box/Enclosure: shelves, cabinets, storage cubes
• Frame: tables, desks, benches
• Vertical stack: bookcases, tower shelves
• Cantilevered: wall-mounted shelves, floating desks
• Freeform: decorative objects, organizers

Step 1.2 -- Load and Stress Analysis

Determine structural requirements:

• Primary load direction (vertical, lateral, distributed)
• Estimated maximum load per surface (kg)
• Racking resistance needs (back panel, cross-bracing, triangulation)
• Span limits for unsupported horizontal panels at given thickness
  • 18mm plywood: max 600mm unsupported span under moderate load
  • 12mm plywood: max 400mm unsupported span under moderate load
• Identify where reinforcement dividers or gussets are needed

Step 1.3 -- Joinery Strategy Selection

Select appropriate joint types based on structural needs:

• Through-slot / tab: Primary structural joints, strongest interlocking method
• Cross-lap (half-lap): For intersecting panels (dividers, grids)
• Finger joints: For box corners requiring maximum glue surface
• Wedge-lock: For tool-free disassembly and reassembly
• Captive-key / butterfly key: For locking joints without glue
• Dado / housed joint: For shelf supports in vertical panels

Step 1.4 -- Tolerance Calculation

Calculate tolerances based on material and cutting method:

• CNC router (6mm bit): Slot width = material thickness + 0.15mm (press fit) to + 0.3mm (sliding fit)
• CNC router (3mm bit): Slot width = material thickness + 0.1mm to + 0.2mm
• Laser cutter: Slot width = material thickness + 0.1mm (account for kerf ~0.15-0.25mm)
• Internal corner radius: Equals bit radius (3mm for 6mm bit) — add dog-bone or T-bone relief cuts
• Always note: "Verify material thickness with calipers before cutting — nominal 18mm plywood often measures 17.5-18.2mm"

============================================================ PHASE 2: DESIGN SPECIFICATION

Step 2.1 -- Design Overview

Write a clear description covering:

• What the object is and its purpose
• Overall assembled dimensions (L x W x H)
• Structural concept (how it stands, resists loads, stays square)
• How the interlocking system works
• Number of unique parts vs total parts
• Estimated assembly time

Step 2.2 -- Parts List

For EVERY part, specify:

For each part also detail:

• Exact slot positions (measured from a consistent datum/reference edge)
• Slot dimensions: width x depth (e.g., 18.2mm x 40mm)
• Tab dimensions: width x length (e.g., 17.9mm x 40mm)
• Corner relief type and radius if applicable
• Any decorative cutouts, handle holes, or ventilation slots

Step 2.3 -- Critical Dimensions Diagram (Text)

Provide ASCII or text-based dimensioned sketches for:

• Front elevation with key measurements
• Side elevation with key measurements
• Each unique part with slot/tab positions marked
• Use consistent datum references (bottom-left corner = 0,0)

============================================================ PHASE 3: JOINERY DETAILS

Step 3.1 -- Joint Inventory

List every joint in the design:

Step 3.2 -- Corner Relief Specification

For each joint with internal corners:

• Relief type: dog-bone, T-bone, or mouse-ear
• Relief radius: match bit radius (e.g., 3mm for 6mm endmill)
• Position: inside corners of all slots

Step 3.3 -- Locking Mechanism (if applicable)

If the design uses tool-free locking:

• Wedge dimensions and taper angle
• Key/butterfly dimensions
• Insertion direction and sequence constraints

============================================================ PHASE 4: CUT LAYOUT STRATEGY

Step 4.1 -- Sheet Planning

Specify:

• Sheet size: standard stock (e.g., 2440 x 1220mm / 4' x 8')
• Number of sheets required
• Material utilization percentage (target > 75%)

Step 4.2 -- Nesting Strategy

Provide nesting guidance:

• Group parts by sheet
• Minimum part spacing: 6mm (for CNC router with 6mm bit) or 2mm (laser)
• Orientation rules:
  • Structural panels: grain direction along longest dimension
  • Shelves: grain direction along span
  • Decorative faces: grain direction consistent across visible surfaces
• Sacrificial tabs / holding tabs: 2-3 per part, 3mm wide x 0.5mm deep (for CNC)

Step 4.3 -- Waste Minimization

• Identify offcuts large enough for secondary use
• Suggest test-cut pieces for joint fit verification
• Note if redesigning any part slightly could improve yield

============================================================ PHASE 5: ASSEMBLY INSTRUCTIONS

Step 5.1 -- Pre-Assembly Checklist

• Verify all parts present against parts list
• Dry-fit test joints (2-3 sample joints) before committing to glue
• Sand slot interiors lightly if fit is too tight
• Lay out parts face-up, organized by assembly step

Step 5.2 -- Step-by-Step Assembly

For each step:

1. Step N: [Action description]
   • Parts involved: [Part A] + [Part B]
   • Joint(s): [J1, J2]
   • Orientation: [which face up, which edge forward]
   • Insert direction: [e.g., slide Part B down into Part A from above]
   • Verify: [what to check — square, flush, level]

Order assembly to:

• Start from the base/core structure outward
• Never require disassembly of prior steps
• Allow glue-up in manageable sub-assemblies
• Keep the object stable at each stage

Step 5.3 -- Finishing Notes

• Glue recommendations: PVA wood glue for plywood/MDF, acrylic cement for acrylic
• Sanding: 120-grit edges, 220-grit faces
• Finish options appropriate to material and use case
• Any post-assembly adjustments (shimming, leveling feet)

============================================================ PHASE 6: CAD / FILE EXPORT GUIDANCE

Step 6.1 -- DXF/SVG Translation Guide

• Each unique part → one closed polyline/path
• All dimensions in mm (or inches if specified — do not mix)
• Slot and tab geometry: draw as exact cut paths, not center-lines
• Include corner relief geometry in cut paths
• Do NOT include dimensions or annotations in cut layer

Step 6.2 -- Layer Organization

Step 6.3 -- CNC Operator Notes

Provide:

• Recommended bit(s): diameter, type (upcut, downcut, compression)
  • Upcut spiral for slots (clean chip evacuation)
  • Downcut spiral for top-face finish quality
  • Compression bit for through-cuts on veneered/laminated stock
• Feed rate and speed suggestions (conservative starting points)
• Depth per pass: max 50% of bit diameter for hardwood, 100% for MDF
• Hold-down method: vacuum table, mechanical clamps, or sacrificial spoilboard with screw-tabs
• Recommended cut order: pockets first, then internal cutouts, then perimeter last

============================================================ OUTPUT

Deliver a single, comprehensive document with all six sections:

1. DESIGN OVERVIEW — Description, dimensions, structural concept, interlocking mechanism
2. PARTS LIST — Complete table with dimensions, features, and slot/tab positions
3. JOINERY DETAILS — Joint inventory table, corner relief specs, locking mechanisms
4. CUT LAYOUT STRATEGY — Sheet count, nesting plan, grain direction, waste notes
5. ASSEMBLY INSTRUCTIONS — Pre-assembly checklist, numbered steps with orientations, finishing
6. CAD / FILE EXPORT GUIDANCE — DXF/SVG rules, layer table, CNC operator notes

All measurements must be in consistent units (mm default). Every dimension must be explicit — no "approximately" or "about". The output must be precise enough that a fabricator can build the object exactly as described without further clarification.

Include this validation checklist at the end:

DESIGN VALIDATION CHECKLIST

• All slot widths account for material thickness + tolerance
• All tabs are slightly undersized for clean fit
• Internal corner radii specified for all slots
• No unsupported spans exceed material limits
• Assembly sequence requires no backtracking
• All parts nest within specified sheet count
• Grain direction noted for all structural panels
• Part labeling system included for assembly reference