Connect Four
For this project, I built a Connect Four game board using the Cameo vinyl plotter, Epilog laser cutter, and Carvey CNC milling machine.
Reflective Log:
3/3/19
Upon deciding to make Connect Four, I brainstormed multiple designs to incorporate a creative flare on the simple game. Considering the game’s setup, I sought to create a Connect Four set that could be compacted when not in use. With this idea, I imagined a two part design where the board would attach to the base in different orientations based on if it was being used or stored away. Realizing my dad’s birthday was also approaching, I decided to decorate the board with his interests in mind. Taking a couple hours to sketch initial prototypes and play with dimensions, I eventually finalized my first design and made a model of it in SOLIDWORKS.
3/4/19
Pitching my project plan to Dr. JAK and the class, a concern brought to me was the structural integrity of a certain overhanging beam with a stress concentration in it. Considering adjustments that could be made, I decided to change the orientation of this piece such that it would not be freely hanging. This in turn changed the side of the base that I would store the board in when not in use. This change resulted in other aspects of my design changing so I went back to SOLIDWORKS and updated my model accordingly.
3/5/19
Today I used Easel to make the coin-shaped game pieces. I decided to use the Carvey CNC milling machine for its dual function of both cutting out the pieces and thinning them so that they clear a ¼” gap. The reason the pieces had to be thinned is because friction would not allow the pieces to slide down the slots. Upon carving the pieces, I had to sand them to get rid of splintering wood around from the edges. This would also make the pieces softer to touch and allow for more clearance when going through the vertical slots. Looking at the base of my Connect Four set (the part holding the board), I used CorelDRAW to laser cut ¼” plywood and acrylic to the necessary dimensions. With the acrylic I was able to cut all the pieces I needed. As for the plywood, I was able laser cut the board (the part where the tokens are used to play the game).
3/9/19
Continuing the with the laser cutter, I was able to cut out the remaining plywood parts such as the bottom shell with engraved images of both my and my dad’s respective high school mascots. Looking more at the interaction of my pieces fitting down the vertical slots of the board and how the pieces would sometimes get stuck, I continued to sand down the tokens and the vertical dividers of the board. With the remaining time, I was able to glue basically all of the base together. This was made possible using acrylic cement for the acrylic to acrylic connections and epoxy for the wood to acrylic connections.
3/10/19
Today I sanded the vertical dividers in my board even more to allow for the pieces to drop smoothly without getting stuck and not dropping to the bottom.
3/11/19
Today I used the CNC mill to carve my plaque which would be placed on the bottom of the base. I was originally going to use aluminum for the plaque but it would have take roughly five hours to complete. I instead used wood and stained it for contrast to the other wood of the base. After more sanding, I eventually glued the two faces of the board. I also had to sand the surfaces of both faces due to a tight fight when sliding it into the board for its compact version. Once the board was sanded to the point that it would fit comfortably, I stained it to a similar look to my plaque.
Conclusion:
Looking at the final product, I’m proud of the way it turned out. Although it was a little rough around the edges, the end result was aesthetic, functional, and special (customized for my dad’s birthday). There were, however, a couple of problems that I ran into. Looking at the laser cutter, I noticed that the acrylic would warp when cut. This resulted in the pieces being cut at slight angles such that some pieces never truly had 90° corners. Moving to Easel and Carvey, I overestimated the strength of the tabs when cutting out my game pieces. This resulted in the tabs being almost useless and the pieces being disconnected from the material. Stopping early, I added more tabs and continued the carve. When it came time to glue my pieces together to make my base, I was too focused on clamping pieces in the correct orientation that I forgot to wipe away the excess glue. This neglect affected other pieces because the excess material dried up and took up space where other pieces were supposed to fit. Lastly, wanting to originally carve my plaque out of aluminum, finding that the carve would take longer than any length of maker lab open hours forced me use a different material. Since I still wanted contrast with the wood that the plaque would be set it in, I decided to use stained wood. In regards to what I would have done differently, I wish I would have given specific connections some wiggle room rather than accounting for kerf and making the connections snug and fighting against friction. This would have saved me a lot time used for sanding. In addition, I would have also wiped away the excess glue for a cleaner look and also for better fitting all around.
Reflective Log:
3/3/19
Upon deciding to make Connect Four, I brainstormed multiple designs to incorporate a creative flare on the simple game. Considering the game’s setup, I sought to create a Connect Four set that could be compacted when not in use. With this idea, I imagined a two part design where the board would attach to the base in different orientations based on if it was being used or stored away. Realizing my dad’s birthday was also approaching, I decided to decorate the board with his interests in mind. Taking a couple hours to sketch initial prototypes and play with dimensions, I eventually finalized my first design and made a model of it in SOLIDWORKS.
3/4/19
Pitching my project plan to Dr. JAK and the class, a concern brought to me was the structural integrity of a certain overhanging beam with a stress concentration in it. Considering adjustments that could be made, I decided to change the orientation of this piece such that it would not be freely hanging. This in turn changed the side of the base that I would store the board in when not in use. This change resulted in other aspects of my design changing so I went back to SOLIDWORKS and updated my model accordingly.
3/5/19
Today I used Easel to make the coin-shaped game pieces. I decided to use the Carvey CNC milling machine for its dual function of both cutting out the pieces and thinning them so that they clear a ¼” gap. The reason the pieces had to be thinned is because friction would not allow the pieces to slide down the slots. Upon carving the pieces, I had to sand them to get rid of splintering wood around from the edges. This would also make the pieces softer to touch and allow for more clearance when going through the vertical slots. Looking at the base of my Connect Four set (the part holding the board), I used CorelDRAW to laser cut ¼” plywood and acrylic to the necessary dimensions. With the acrylic I was able to cut all the pieces I needed. As for the plywood, I was able laser cut the board (the part where the tokens are used to play the game).
3/9/19
Continuing the with the laser cutter, I was able to cut out the remaining plywood parts such as the bottom shell with engraved images of both my and my dad’s respective high school mascots. Looking more at the interaction of my pieces fitting down the vertical slots of the board and how the pieces would sometimes get stuck, I continued to sand down the tokens and the vertical dividers of the board. With the remaining time, I was able to glue basically all of the base together. This was made possible using acrylic cement for the acrylic to acrylic connections and epoxy for the wood to acrylic connections.
3/10/19
Today I sanded the vertical dividers in my board even more to allow for the pieces to drop smoothly without getting stuck and not dropping to the bottom.
3/11/19
Today I used the CNC mill to carve my plaque which would be placed on the bottom of the base. I was originally going to use aluminum for the plaque but it would have take roughly five hours to complete. I instead used wood and stained it for contrast to the other wood of the base. After more sanding, I eventually glued the two faces of the board. I also had to sand the surfaces of both faces due to a tight fight when sliding it into the board for its compact version. Once the board was sanded to the point that it would fit comfortably, I stained it to a similar look to my plaque.
Conclusion:
Looking at the final product, I’m proud of the way it turned out. Although it was a little rough around the edges, the end result was aesthetic, functional, and special (customized for my dad’s birthday). There were, however, a couple of problems that I ran into. Looking at the laser cutter, I noticed that the acrylic would warp when cut. This resulted in the pieces being cut at slight angles such that some pieces never truly had 90° corners. Moving to Easel and Carvey, I overestimated the strength of the tabs when cutting out my game pieces. This resulted in the tabs being almost useless and the pieces being disconnected from the material. Stopping early, I added more tabs and continued the carve. When it came time to glue my pieces together to make my base, I was too focused on clamping pieces in the correct orientation that I forgot to wipe away the excess glue. This neglect affected other pieces because the excess material dried up and took up space where other pieces were supposed to fit. Lastly, wanting to originally carve my plaque out of aluminum, finding that the carve would take longer than any length of maker lab open hours forced me use a different material. Since I still wanted contrast with the wood that the plaque would be set it in, I decided to use stained wood. In regards to what I would have done differently, I wish I would have given specific connections some wiggle room rather than accounting for kerf and making the connections snug and fighting against friction. This would have saved me a lot time used for sanding. In addition, I would have also wiped away the excess glue for a cleaner look and also for better fitting all around.
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