Bent Lamination - The Wood Whisperer

Why Bent Lamination?

With regards to chopping curves, the simplest solution to get the job completed is to easily cut the curve from a bit of strong wood. However strong wood has vital limitations. Some curves would require a bit of inventory so thick that it might not solely be extremely wasteful, however you aren’t more likely to discover the wood within the first place. The second situation comes right down to stability. If you cut a curve in a straight-grained piece of strong wood, you inevitably create weak level the place the curve cuts throughout the grain (a state of affairs referred to as “brief-grain). So your greatest guess with heavilyt-curved elements is to both steam mattress the fabric to form or do a bent lamination. Pictured left you possibly can see a closeup of one of many rockers on my Maloof-Impressed Rocker. This can be a good instance of a state of affairs the place bent lamination is an effective selection.

The way it Works

The idea is definitely fairly easy. Thick boards don’t bend well however skinny ones do. So we merely cut a board into skinny strips in order that when bundled collectively, the strips can flex to the specified form. With glue between every lamination, a press is used to bend the bundle of laminations round a type. As soon as the glue dries, the workpiece will maintain it’s new form. So the primary order of enterprise is to construct the shape adopted by slicing the wood into lamination strips.

The Bending Type

There are various methods to assemble a type and apply strain. The means I discovered to do it leaves little room for error and produces a type that may be re-used time and time once more. Utilizing three/four″ plywood, I cut and finesse the specified form after which construct the stack as tall as I want. A flush trim bit makes positive every layer conforms to the form completely. I then create a unfavourable of the curved profile that may function the caul, making use of strain to the laminations and pushing them into the shape. This unfavorable takes into consideration the thickness of the bent piece in order that the curves match up completely with no lifeless area, as soon as the stack is positioned between them. I additionally like to make use of cork on the bending surfaces to assist distribute the strain evenly. The whole type is roofed in packing tape to stop the glue from sticking. Wax is a good suggestion as well for a belt and suspenders strategy.

The Strips

The strips are often cut on the bandsaw, a software that excels at resawing. A desk noticed may be used. How skinny you cut the strips will depend on numerous elements, embrace the wood’s pure bending properties, the severity of the curve, and your tolerance for springback. 1/eight – 1/four″ is widespread however I often find yourself someplace round three/sixteen″. As soon as the strips are cut, they must be smoothed out and introduced right down to ultimate desired thickness. I often use my drum sander for this activity however a planer can be utilized as well.

The Adhesive

There are various glues available on the market and simply as many faculties of considered which glue works greatest. For my part, an excellent inflexible glue line will present the most effective lengthy-time period outcomes. That may be resin glues like DAP Weldwood and Unibond 800 and in addition epoxy. However many people will use normal PVA glues of their laminations with no hassle in any respect. In reality, that’s what Sam Maloof himself utilized in his chairs so I made a decision to attempt it on mine. I used Titebond Prolong for the additional working time. I’ll let you realize in a couple of years if it decides to de-laminate. The glue is utilized to every strip utilizing a glue curler for expedience.

What Now?

As soon as the laminates are within the press, depart them beneath strain in a single day. The subsequent day, you may want a mallet or lifeless blow hammer to pop the workpiece out of the shape. At that time I often sand the surplus glue off the floor after which joint and aircraft as wanted.

When you perceive how this course of works, it actually opens up the playbook of design prospects! Give it a shot!

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