---
title: Tips & Tricks for furniture development.
slug: tips--tricks-for-furniture-development
description: Achieving a smooth and glossy finish is essential. The aim is to make plastics appear attractive and high-quality.

We outline the process to create an HDPE cradle that can be transformed into two rocking chairs. Tips and techniques are provided to attain a shiny finish and conceal screws or fixings effectively.
tags: ["HDPE","product"]
category: Products
difficulty: Medium
time: < 1 week
location: Ensenada, Mexico
---
import { Image } from 'astro:assets'
# Tips & Tricks for furniture development.
<Image src={import('./NEON--EXPLOTED-180125828e0.png')} alt="Tips & Tricks for furniture development." />
Achieving a smooth and glossy finish is essential. The aim is to make plastics appear attractive and high-quality.

We outline the process to create an HDPE cradle that can be transformed into two rocking chairs. Tips and techniques are provided to attain a shiny finish and conceal screws or fixings effectively.

User Location: Ensenada, Mexico
## Steps
### Step 1: The whole process summarized in a 1-minute video.

### Assembly and Finishing Process

This video outlines the steps involved in assembling and finishing the cradle. The following instructions cover essential details about the materials and tools used.

### Step 2: Sheet manufacturing and CNC parameters.

The process was developed by Blue Phoenix Plastic Mexico. The method of manufacturing plastic sheets affects the surface finish. To achieve a smooth finish, apply a mold release and use a polished surface.

CNC parameters:

- CNC Router: Makita 3709, 110 V, 530 W, 30,000 rpm.
- CNC Router Bit: ARMG-808-L Melin Tool (1 Flute, Carbide, Dia: 1/4 in, LOC: 1-1/4 in, OAL: 3 in, Shank: 1/4 in, Single End, Helix 30°).
- Spindle Speed: 30,000 rpm.
- Cutting Feedrate: 94.5 in/min (2400 mm/min).
- Plunge Feedrate: 11.8 in/min (300 mm/min).
- Maximum Roughing Stepdown: 0.047 in (1.2 mm).


<Image src={import('./IMG_5387-1801653f35d.jpg')} alt="IMG_5387-1801653f35d.jpg" />


<Image src={import('./Router_Bit-1801657c5e0.png')} alt="Router Bit-1801657c5e0.png" />

### Step 3: Achieve a specific and constant thickness.

When producing plastic sheets, thickness may vary between batches. If a specific thickness is required, a wood planer can be used.

Save the plastic remnants, as they are ready for future use. In this project, these remnants were utilized for the next step.

Hardware:

- Ryobi AP-10 planer.


<Image src={import('./Image2-180169d22a0.jpg')} alt="Image2-180169d22a0.jpg" />

### Step 4: Repair bubbles or holes inside or on the sheet.

Even industrially produced recycled plastic sheets may have imperfections. These can be repaired using the same material.

Employ a heat gun or hair dryer and shape leftover material into a ball slightly larger than the hole. Pre-heat the affected area and, using a flathead screwdriver, press the plastic ball into the hole, applying additional heat if necessary.

Leave extra material to ensure complete filling; excess can be sanded off.


<Image src={import('./Image3-180169e116e.jpg')} alt="Image3-180169e116e.jpg" />


<Image src={import('./Image4-180169e1f03.jpg')} alt="Image4-180169e1f03.jpg" />


<Image src={import('./Image5-180169e2c71.jpg')} alt="Image5-180169e2c71.jpg" />

### Step 5: General sanding.

### Surface Finishing Process

The quality of the HDPE sheet's surface affects the finishing process. If the surface is rough, it can be sanded manually or with a band or orbital sander. Using a wood planer for a specific thickness may result in a rough surface, necessitating the use of wet-dry sandpaper. We used grits in this order: 220, 320, 400, 800, 1200, 2000.

For a smooth edge finish, utilize a worn belt on a band sander. Applying pressure against the rotating belt can melt the rough edge, resulting in a smooth finish within seconds.


<Image src={import('./Image6-180169b220e.jpg')} alt="Image6-180169b220e.jpg" />


<Image src={import('./Image7-180169b35d5.jpg')} alt="Image7-180169b35d5.jpg" />


<Image src={import('./Image8-180169b4291.jpg')} alt="Image8-180169b4291.jpg" />

### Step 6: Getting rid of TABS post CNC cutting.

### Process for Removing Tabs and Smoothing Edges

This step applies to sheets cut with CNC leaving tabs for attachment during transportation. It also ensures smooth edge finishes.

Using a CNC Router at 35,000 RPM with a flush trim CNC Router bit effectively removes the tabs and refines the edges.

#### Required Tools:

- Amana Tool - 47100 Carbide Tipped Flush Trim 3/8" Diameter x 1/4" Shank
- Bosch CNC Router, Colt 1-Horsepower, 5.6 Amp, Electronic Variable-Speed, Model PR20EVS


<Image src={import('./Image10-18016b25622.jpg')} alt="Image10-18016b25622.jpg" />


<Image src={import('./Image9-18016b1e24f.jpg')} alt="Image9-18016b1e24f.jpg" />


<Image src={import('./Untitled_2-18016b2f919.png')} alt="Untitled 2-18016b2f919.png" />

### Step 7: Strategic location of screws and fixings.

The design process is fundamental, even though it is interlinked with subsequent steps.

Concealing screws and fixings can create a seamless appearance. An important design choice involves selecting the material and head type of screws. For this furniture, stainless steel flathead socket screws were used.

It is important to plan screw placement to ensure they remain hidden or less visible during use. In this instance, the sides of the rocking chairs were divided into two profiles. This approach conceals the structural screws with an additional profile, enhancing mechanical strength while providing an exterior without visible screws.


<Image src={import('./DESPIECE_1-18016c735cb.jpg')} alt="DESPIECE 1-18016c735cb.jpg" />


<Image src={import('./DESPIECE_2-18016c75516.jpg')} alt="DESPIECE 2-18016c75516.jpg" />

### Step 8: Screws installation.

This process can be completed using a CNC machine. However, due to varying thicknesses in the plastic sheets, it was done manually.

A countersink bit was employed to ensure the screw head is level with the sheet.


<Image src={import('./Image11-18016e48038.jpg')} alt="Image11-18016e48038.jpg" />


<Image src={import('./Image12-18016e49ce2.jpg')} alt="Image12-18016e49ce2.jpg" />


<Image src={import('./Image13-18016e4ac40.jpg')} alt="Image13-18016e4ac40.jpg" />

### Step 9: Photo shoot.

### Photography Tips for Makers

A quality product deserves attractive photos to showcase the effort involved in its creation.

**Lighting**: The most crucial aspect of photography is lighting, even more so than the camera's quality.

**Instructions for Small Products**: Use colorful cardboard as a backdrop, find an outdoor space with good lighting, and take numerous photos from various angles to ensure you have multiple options.

**Example**: View a photo shoot for a screwless plant mold [here](https://www.instagram.com/p/CbCgXJClI3f).


<Image src={import('./20220326_194529-18017003d13.jpg')} alt="20220326_194529-18017003d13.jpg" />


<Image src={import('./20220326_185321-180170051da.jpg')} alt="20220326_185321-180170051da.jpg" />


<Image src={import('./20220312_145518-18017005b61.jpg')} alt="20220312_145518-18017005b61.jpg" />