Slab Leveling Jig

Overview

In recent years, there has been an increasing demand for large wooden slab furniture. However, there is not currently a cost-effective product available that allows woodworkers to efficiently level a wood slab. There are planers and CNC routers available that can quickly level a slab, but these machines are incredibly expensive and not affordable for most woodworkers. Our team’s task was to create a jig, compatible with several routers that woodworkers can use to level a slab of wood.

Objectives

Our team went through a tedious concept generation and selection process to determine the best materials and motion systems for translating a router across a piece of wood. Each of these decisions took into account our sponsors needs and our team’s budget. Once these design choices were made, we constructed prototypes of the jig and tested them to ensure a quality product for consumers.

Approach

– Spoke with our sponsor, reviewed their notes, and researched current processes that woodworkers use to determine customer needs

– Based on customer needs, we used a concept mapping method to determine the necessary functions of the jig

– Breaking down each system of the jig and knowing its functionality allowed us to make the best design choices for our prototypes

– Our initial prototypes consisted of SolidWorks CAD models which allowed us to see all the parts needed for the jig and how they would interact with one another

– After settling on a good CAD design, we ordered many of the parts that we would need to construct an initial prototype to test one of our translational movement systems

– Once a first prototype was constructed, we recognized a few issues with how the system moved the router

– Based on these issues, we adjusted our design to make the system more stable which made motion easier

– Once this first system was satisfactory, we moved onto the design of our second translational system

– This second system was more complex than the first and required more testing, but eventually both systems worked together to successfully move the router across the entire jig

Outcomes

– The team created a new product allowing the sponsor to have one of the only affordable slab leveling jigs available to customers.

– The sponsor will save approximately $250 compared to similar systems on the market as a result of this project.

– By utilizing a threaded rod and gear system, cutting times were reduced and more accurate cuts were produced.

– In future applications, the project can be automated to move in the X and Y directions.