Mallet-Based Assembly: Enabling Load-Bearing Laser-Cut Models
summary
Laser-cut, load-bearing assemblies require mallet-tight joints but often break or block during hammering; the paper analyzes 400 tension-critical models, identifies 10 failure modes in two groups (plate breaks, block-assembly errors), and ships two fixes: trapezoidal scaffolding (hit-friendly, breakaway scaffold tabs) and a branch-and-bound algorithm that computes a constraint-before-insertion assembly order. A user study shows non-experts assemble ~2× faster, scaffolding speeds 14% of operations yielding 1.3× per-model speed-up, and 70% of models benefit from reordered assembly.
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chapters (11)
- 0:00Introduction
- 0:24Load-bearing laser-cut models
- 1:29Forces and joint issues
- 3:14Mallet-based assembly concept
- 3:58Trapezoidal scaffolding solution
- 5:46Error tolerance in assembly
- 7:55Constraint before insertion
- 9:18Assembly order algorithm
- 10:21User study results
- 10:44Conclusion and thanks
- 11:27Q&A session
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