manufacturing plan

Innovation Space

Manufacturing Plan

Basic Wood Working• Cost: $50• Tools:Ryobi Japanese hand saw, marking knife, layout square, sandpaper, clamp, chisels, brace and bit, drill bits, wooden mallet• Uses simple hand tools and a basic power jigsaw to cut female grooves and male connectors into wood for mortise and tenon, dovetail,

dado and dowel joints

PVC Connections• Cost: $10-15 for pipes, $1-3 for connectors• Tools: PVC cutter, brace and bit• Uses pvc pipe, pre-made pvc connectors and simple hand tools to assemble pvc pipes

Bamboo Joinery• Cost: $20 for tools, $3 for rope • Tools: hand saw, hammer, file• Uses simple tools and rope to create bamboo joints

Universal Joint• Cost: $20 for tools, $5 for sheet metal• Tools: metal sheers, sheet metal punches, hammer• Uses sheet metal working tools to hand mold a connector that can be used to connect things

Structures• Metal to Wood –Bracing and trusses• Strawbale—Pin Joints• Mud Bricks

Odds and Ends Joints• C-Clamps• Tie-Wraps

How We Build

Methods for building in the Innovation Space with limited

power tools and skill sets

Basic Wood Working• Cost: $50• Tools:Ryobi Japanese hand saw, marking knife, layout square, sandpaper, clamp,

chisels, brace and bit, drill bits, wooden mallet, block plane, waterstone• Uses simple handtools and a basic power jigsaw to cut female grooves and male

connectors into wood for mortise and tenon, dovetail, dado and dowel joints

Basic Wood Working• Pros: wood is locally available, very sturdy structures, easy

to cut• Cons: requires a lot of skill for certain joints, time

consuming3. Mortise and tenon joint (top right picture ‘A’)

Tenon – rectangular protrusion from the male jointMortise – female joint with a square opening

• Measure and mark the tenon; use the saw and chisel to cut

• On the female joint, measure and mark where the mortise will be

• With the largest drill bit, drill through the center of the mortise square and use a chisel to square the rest of the piece

• Fit the tenon in the mortise; drill a hole for the dowel on the protruding portion of the tenon

• Hammer the dowel the hole to secure the tenon in place

Basic Wood Working• Pros: wood is locally available, very sturdy structures, easy

to cut• Cons: requires a lot of skill for certain joints, time

consuming

3. Sliding Dovetail joint (top right picture ‘B’)

• Mark and measure the dovetail; a taper of 3-5 degrees is recommended

• Cute the dovetail and sand it until the edges are rounded and smooth

• To cute the dovetail groove, clamp the dovetail to the female joining piece and use it as a guide for the saw; cut

• Chisel the groove and sand until the dovetail fits securely

Basic Wood Working• Pros: wood is locally available, very sturdy structures, easy

to cut• Cons: requires a lot of skill for certain joints, time

consuming

1. Dado Joint (top right picture ‘C’)

• Measure and draw the groove cut length wise on the mating piece

• Cut each side of the groove ¼- 1/2 inch down

• Use a hammer and chissel to remove the wood for the groove

• Hammer the joining piece in place

Basic Wood Working• Pros: wood is locally available, very sturdy structures, easy

to cut• Cons: requires a lot of skill for certain joints, time

consuming

2. Dowel Joint (top right picture ‘D’)

• Measure and draw the spacing for the dowels on both pieces that are to be joined

• Drill half the length of the dowel down on each side

• Hammer the dowel into the holes on one piece • Match up with the joining parts holes, hammer in

place

PVC Connections• Cost: $10-15 for pipes, $1-3 for connectors• Tools: PVC cutter, brace and bit• Uses pvc pipe, pre-made pvc connectors and simple hand

tools to assemble pvc pipes

PVC Connections-Pros: initial low cost, light weight-Cons: not as durable as clay piping

1. The first step is to apply the primer to the fitting and pipe ends. The PVC Primer will soften and prepare the PVC Fitting or PVC pipe length for the cement that will be used when connecting.

PVC Connections-Pros: initial low cost, light weight-Cons: not as durable as clay piping

2. Next, choosing the cement may be the most important step in the process. Before applying the cement, you need to stir it well.

PVC Connections-Pros: initial low cost, light weight-Cons: not as durable as clay piping

2. After stirring, liberally apply it to both the pipe end and fitting socket. Add one more layer of cement to the pipe end, and then quickly assemble the fitting and pipe, ensuring a full and complete connection. Finally, wipe away the excess and let it dry

Bamboo Joinery• Cost: $20 for tools, $3 for rope • Tools: hand saw, hammer, file• Uses simple tools and rope to create bamboo joints

Bamboo Joinery: How To Basics• Pros: environmentally benign, sustainable, available locally, durable,

seismic resistant, easy to cut

• Cons: circumference variations makes joining difficult, no standard in universal joinery that is strong and affordable

1. Identify nodes – thick rings; these are needed for both ends of the joints or else the bamboo will splinter

bamboo joint node

Bamboo Joinery: How To Basics• Pros: environmentally benign, sustainable, available locally, durable,

seismic resistant, easy to cut

• Cons: circumference variations makes joining difficult, no standard in universal joinery that is strong and affordable

2. Similar to tube fitting (this bicycle frames), bamboo joint cuts have a male cut that fits into a female groove on the connecting piece

bamboo male cuts

Bamboo Joinery: How To Basics• Pros: environmentally benign, sustainable, available locally, durable,

seismic resistant, easy to cut

• Cons: circumference variations makes joining difficult, no standard in universal joinery that is strong and affordable

3. Cord or a dowel system (above left inset) can be used to secure the joint; wood nails will splinter the bamboo

Securing a bamboo joint

Universal Joint• Cost: $20 for tools, $5 for sheet metal• Tools: sheet metal shears, sheet metal punches, hammer• Uses sheet metal working tools to hand mold a connector that can

be used to connect things

NCIIA Cameroon Project Leslie Speer, San Jose University

"Reverse Engineering Bicycles to Develop New Businesses, Products and Increased Income for the Metalworking and Agriculture Industries in Lebialem (Cameroon)".

Universal Joint• Cost: $20 for tools, $5 for sheet metal• Tools: sheet metal shears, sheet metal punches, hammer• Uses sheet metal working tools to hand mold a connector that can

be used to connect things

1. Cut shapes out of sheet metal with metal sheers and punches (drawings can be found at http://cameroonprojectnciia.blogspot.com/ )

2. Hammer sheet metal to shape of connector

How We Connect

Methods and options for connecting similar materials,

mixed materials and hardware to projects in the Innovation

Space

Simple Structureso Mud bricks

shaped with wooden molds

o Dries in the Sun

o Clay+Straw+Water (simple materials)

Straw Bale

Sand and cement mixture

Straw and soil mortar

Straw bale Connection

Attach around secured pole

Blocks Pinned together

Woodworking: Pegs

Uses: 1. Furniture2. Vehicles3. Small

Structures

Metal Joints: TrussesMetal->Wood connections

Simple Mechanisms: Materials to Material

C-Clamp

Tie-Wrap

“Usables”: Materials to HardwareCasters Bolt and Lock Nut

Casters have four pre-drilled holes around it’s top support. They can easily attach to a flat surface using bolts and nuts.

Non-swivel wheels can attach using a bolt, spacer and lock nut assembly.

“Usables”: Materials to HardwareSurface Mount Hinge Mortise Mount Hinge

Attached to the door or frame; uses screws to secure

Mounted into recessed cutouts (mortises) on door's edge; uses screws to attach

“Usables”: Materials to HardwareEyebolts to Hooks Eyelbolt to Rope

An eye bolt screw could provide an easy connection to a carabineer style hook for a removable item, such as a bag that fits into a cart or to secure an item onto a cart

A simple way to secure items on a cart would be to attach an eye bolt to the frame of the cart in appropriate locations and use rope to secure it in place