Final DXF File

I've sourced my plywood and this is the final DXF file I will be sending to the routers.

I need 25 pieces to make up 450mm. There are 2 end pieces 23 cut pieces and 23 non-cut pieces.

Rubber Material

I took photos of the final rubber material contrasted against the 1:1 prototype to see the colour contrast and to imagine how the final product will look.

Final Prototype

The laser cuts proved a success, so i added ribbon between the pieces to simulate where the rubber would go. I worked out I need 15m of rubber and I sourced 18m.

1:1 Scale Model - Laser Cut

After I had my dxf file cut to size, this is the result. There was a slight mistake with my material, and rather than have the ply 18mm wide, it was cut out of 5mm hoop pine - which I was ok with since it would let me get a sense of just how much rubber I would need.

After being happy with the size, I thought it would be time to create a 1:1 scale mockup of the entire product, so using offcuts from a different source of wood, (10 mm thick), I glued the pieces between the laser cuts and created a close width to the actual product.

The final length and width is 1:1. The depth is short by 150mm.

1:1 Drawings with model

After I had my designs laser cut, I tried them out on the 1:1 Scale Drawing.

Exploded View

Exploded view of the original assembly. Hopefully this layout works for the building process. May change slightly

Prototypes

The Image below is what I want my final design to look like once the dxf files have been worked out.

There will be more radius on all the edges and it will be cut into 25 pieces of 18mm exterior grade ply

Below is my first attempt at a prototype. The scale is 1:5 so you can imagine its a little small, but the scaled size and dimensions are perfect.

DXF Files - Beginning

DXF file tries

Final DXF file that I satisfied on. Will get this laser cut and try prototypes out for size and work out my errors.

Final Concept Developement

 had to work out a system that would allow me to use to support the rubber while it was in tension, coupled with the added weight it would need to support once the user sat on it.

 with help, worked out several cuts of plywood (exterior grade 18mm) would satisfy the strength requirement and work out very well. From here I need to work on a dxf file for a cnc router.