Wikihouse Build - Preparing Calibration Test Part Files

We’re going to to cut a wikihouse.cc to see what options we have for interior structures in a new workspace plan. We’ve been looking into shipping containers but they’re not turning out to be as cheap since shipping is on the rise or as easily modified as we’d like. Welding and plasma cutters are not on our list right now.

Wikihouses are constructed from plywood cut on a CNC router. Browsing their library of designs, we decided to build a Gwangju Prototype which is a Korean wikihouse design.

Getting Started

To get going, we first need to pass the Wikihouse Calibration Test. This is a small collection of parts to test the accuracy of your machine and a simple build of the common locking joint.

What We Used

1. SketchUp Pro 2013 (SU2013)
2. Wikihouse Plugin from the SketchUp Extension Warehouse
3. Adobe Illustrator CS6 (AI)
4. VCarve Pro 7.5 - ShopBot Edition (VCP)
5. ShopBot PRS96 / Porter Cable Router

What We Did

File Conversion

1. Opened Calibration Test in SU20132. Used Wikihouse Plugin to Export parts as SVG3. Opened SVG in Adobe Illustrator and converted to EPS.

Creating Shopbot File

1. Opened Wikihouse Calibration EPS we converted in VCarve Pro
2. Locked objects together when parts had internal pockets.

This keeps the alignment of pockets when we move a part around.

3. Nested parts using:

a. 0.5” for Tool Dia, Clearance and Border Gap

b. 90deg Rotational step angle

c. nest from bottom left

d. Nest Along X

This resulted in parts fitting in a 48”x48” piece of plywood so we can get two attempts per full sheet.

4. Unlocked all groups so we can edit the objects again.

5. Added 0.125” Dog-Bone fillets for toolpaths.

The Wikihouse designs from Sketchup are laid out as ideal. Since we are cutting on a router, we can’t cut perfect right angles on internal pockets as drawn. The solution is to cut Dog Bones/T-Bones where extra material is removed on the interior corners. The parts will then fit together correctly.

6. Since we have excess material, more locking parts were added to the sheet reducing waste.

7. “0 Mark Hold-down” toolpath created to mark material where drywall screws can safely attach material to ShopBot spoilboard. 0.3” dia circles (slightly larger than our 0.25” bit) are cut 0.2” deep around the material. Screws prevent material from moving and reduce any warp in the plywood.

8. “1 Cut Out Parts” toolpath is created for the main parts. All parts are cut using a Profile path with tabs added.

9. “2 Label Parts” toolpath is created so each main part has a unique id. Now if a part has a problem, we can fix it in the part file easily. This project only uses two identical parts but labeling is still a good idea.

10. “3 Cut Out Locks” toolpath is created to machine the extra lock parts we added to use up the material.

11. Save ShopBot files.