From Freeform Model to Solid-Wood Parts
Together with Hoffmann Interior, we developed the digital planning for a freeform counter with fronts made entirely of solid wood. We supported the planning and supplied the 3D data and Grasshopper scripts. Hoffmann Interior carried out the fabrication in its own workshop.
Fabrication at Hoffmann Interior
Hoffmann Interior glued up the blanks and milled them on its CNC machining centre, based on the 3D data. Assembly and surface finishing were also carried out in its own workshop.
The Challenge: Freeform Fronts in Solid Wood
A curved front cannot simply be cut from a panel. Each segment first has to be glued up from solid-wood boards and then milled to its final shape. Because the counter is freely curved, almost every segment is different, which raised several questions:
- How can a suitable milling model be created for every segment without modelling each one by hand?
- How much wood is needed, and in which lengths and widths does it have to be prepared?
- How can each blank be fixed securely on the machine?
- How do the many individual pieces find their exact place during assembly?
The Grip Recess: Milled Directly into the Wood
A defining detail of the counter is the grip recess, which is milled directly into the solid wood instead of being added as a separate part. We built it into the parametric model in such a way that the router could reproduce the digital geometry exactly. If the geometry changes, the recess is updated with it.
An Automatic Milling Model
A Grasshopper script generates the complete milling model from the geometry of a segment: the stacked boards around the form, the milling body and the side parts used to hold it on the machine. The boards are arranged as closely as possible around the segment to reduce material waste.
The Grasshopper script: from the segment geometry to the exported milling model.
Estimate and Bills of Materials and Milling Template
For each segment, the script also produces a bill of materials. This made it possible to estimate early on how much wood was needed and in which lengths and widths it had to be prepared.
A PDF is created for each milling body, with the main dimensions in several views, a laying plan listing the board layers from bottom to top, and the parameters used. The workshop can therefore check every part before it goes on the machine.
All individual pieces were planned and numbered so that they could be clearly identified in the workshop and assembled into the complete counter without confusion.
Planning a Freeform Project in Solid Wood?
Whether it is a counter, a reception desk or a piece of custom furniture: we prepare complex geometry so that your work preparation and CNC team can use it directly. Get in touch and tell us about your project.