Boxes, cartons and more, ready to cut
190 parametric designs from ParametrIQ CAD's library: FEFCO and ECMA boxes, and designs for every trade it serves. Size one in the viewer, or download it as DXF or PDF.
Carpentry
Arch template
Carpentry: a template (a turning piece) for an arched opening or a curved head: cut from sheet, it gives the arch's soffit (the intrados) to build a brick arch on or to mark a curved timber head from. The arch is segmental (a part of a circle, of a given span and rise), semicircular, or pointed (two arcs, each struck from the other springing point). The template stands on a strip below the springing line, so it can be wedged up on props and struck after. The springing line, the striking points (the centres) and, if wanted, the arch ring and its joints (bricks of 65 and a 10 joint, measured round the soffit, an odd number so there is a key brick) are on layer 8. Sizes: the clear span between the springing points, and the rise to the crown.
Carpentry
Bookcase
Carpentry: a bookcase of sheet material or boards, its parts laid out side by side as a cutting list: two sides with housings (dados) for the shelves, a rebate across the top for the top, and a rebate up the back edge for the back panel; the top, the fixed shelves (the lowest is the bottom), the plinth under the bottom shelf, and the back. The housings and rebates are marked on layer 8 (a third of the board deep for the shelves, half the sides for the back), with the labels. The sides are a pair, drawn from their inside faces. Sizes are outside sizes. Shelves of 18 mm board much over 800 long will sag under books: add a fixed upright, or use thicker board.
Carpentry
Cabinet carcass
Carpentry: a base cabinet carcass (a kitchen or workshop cupboard, for a worktop on top), its parts laid out as a cutting list: two sides with a housing (dado) for the bottom, rebates across the top for a front and a back rail, a rebate up the back edge for the back panel, and the toe kick cut out at the front; the bottom, the two rails, an adjustable shelf, and the back (on layer 22, its thinner board). The housing and the rails' rebates are marked on layer 20 (a third of the board deep), the back's rebates on layer 21 (half the board deep), the shelf-pin holes (a row each side, every 32 mm) on layer 23. The sides are a pair, drawn from their inside faces. Sizes are the carcass's outside sizes. The 3D page shows the carcass put together, step by step.
Carpentry
Common rafter
Carpentry: a common rafter for a pitched (gable) roof, drawn on its board as a pattern rafter to mark the rest from: the plumb cut at the ridge, the birdsmouth (the seat cut that sits on the wall plate and the heel cut against its outside face), and the tail at the eaves, cut plumb, or plumb and level for a soffit. The span is across the outside faces of the wall plates; the ridge board's thickness is taken off the run. The seat is no longer than the wall plate is wide, and the birdsmouth no deeper than a third of the rafter. The timber sets the rafter's size: check it against span tables for your roof's loads and your building regulations.
Carpentry
Dovetail template
Carpentry: a marking template for a through-dovetail joint: the end of the tail board, seen on its face, with its tails cut to shape, and the end grain of the pin board with the sockets the tails go into. Cut it from thin sheet (or print it) to mark both boards, or check a layout. The tails are spaced evenly between a half pin at each edge; the pins are narrowest on the pin board's outside face. The slope is 1 in 6 for softwood, 1 in 8 for hardwood. The baselines are a board's thickness from the ends (both boards the same thickness); the pin board's end and the labels are on layer 8.
Carpentry
Mitred picture frame
Carpentry: the four mitred pieces of a picture frame, cut from a rebated moulding, laid out flat with their outside edges down: two for the top and bottom, two for the sides. The picture's size and the mount's border set the glass (and the backing board); the rebate is cut a little bigger than the glass so it drops in, and the lip of the moulding covers the glass's edge, so the sight size (the opening) is smaller than the glass by the lip each side. The moulding sets its face width, the lip and the rebate's depth (room for the glass, the mount and the backing). The rebate is marked on layer 8, from the sight edge to its wall, with the labels. Allow a saw cut between the pieces when you cut them from one length of moulding.
Carpentry
Pergola rafter tail
Carpentry: a template for the end of a pergola's rafters (or joists): the shaped tail cut under the end, angled, round, cove (hollow), ogee or stepped, and the notch that sits over the supporting beam. Cut it from thin sheet, lay it on each rafter with its top edge to the rafter's top and its end to the rafter's end, and draw round it. The top third of the depth is kept full to the end, so the shape shows below. Sizes: the overhang from the rafter's end to the beam's outside face, and the shaped length; the notch is a quarter of the rafter deep and as wide as the beam. The template's far end (cut square) is a beam's width past the notch.
Carpentry
Shaker door
Carpentry: a Shaker-style frame and panel door, its parts laid out for marking: two stiles (the uprights, full height) and two rails (between them), grooved along their inside edges for a flat panel, joined with stub tenons that fill the groove or with haunched mortise and tenons. The groove's depth and the mortises are marked on layer 8, with the labels. The panel is cut to the frame's opening plus the groove's depth each side, less a gap for it to move (more for solid timber, which swells and shrinks across its grain). Sizes are the door's.
Carpentry
Stair stringer
Carpentry: a cut stringer for a straight flight of stairs: the steps cut out of a board, a seat cut at the foot and a plumb cut at the top. The total rise (floor to floor) is shared equally between as few risers as keep each under the largest rise allowed; the timber chosen sets the board's width, and the throat (the board left under the cuts) is worked out. Check the rise, going and pitch against your building regulations: the figures printed are the UK's for a private stair (2R + G from 550 to 700, pitch no more than 42°).
Carpentry
Table legs and aprons
Carpentry: the frame of a table: four square legs joined by aprons with mortise and tenon joints, laid out for marking: a leg's two inside faces, unfolded at its inside corner, with the mortise in each (marked on layer 8) and, if wanted, the taper below the aprons; a long and a short apron, each with a tenon at each end. The top overhangs the legs all round. The aprons are set back from the legs' outside faces; the tenons are a third of the apron's thickness, shouldered top and bottom, and run two thirds into the leg, so mitre their ends where they meet inside it. Sizes are the top's and the height overall; the top's thickness is taken off the legs. Labels on layer 8.
Carpentry
Workbench
Carpentry: a workbench, its parts laid out as a cutting list: the top, four legs, long rails at the top and near the floor (front and back) let into housings in the legs, end rails bolted across the legs at the same heights, and a shelf on the lower long rails. The housings (a third of the leg deep), the rails' positions and the labels are marked on layer 8. The top overhangs the frame at the ends (room for a vice) and a little at the front and back. Sizes are the top's and the height to its surface.
Carpets and flooring
Door mat with logo area
Carpets and flooring: a door (entrance) mat: its outline in a standard size (or your own), the corners rounded, cut (layer 0); a border of plain colour round a logo area in the middle (the logo area's outline, its centre lines and its size on layer 8), and the border's inner edge on the Border layer. The logo is inlaid or printed in the area.
Carpets and flooring
L-shaped room cut plan
Carpets and flooring: an L-shaped room's carpet cut plan: the room's outline (layer 0) from its sizes, the carpet laid in drops the roll's width wide with the pile running the way chosen, the seams between them (on the Seams layer), each drop numbered with its length, and below the room the cutting plan: the lengths cut from the roll one after another, each the drop's length and a trim allowance at both ends, with the drop's shape in it. The roll length needed and the waste are worked out (ROLLLENGTH, FLOORAREA). The seams start from the room's first corner, moved along by the seam offset to keep them out of the main traffic way.
Carpets and flooring
Oval rug
Carpets and flooring: an oval rug: its outline (an ellipse) cut on layer 0, the border's inner edge and the binding's on the Border layer (insets of the outline: OFFSET, so they follow its size), and an arrow showing the way the pile runs (along the rug).
Carpets and flooring
Rectangular rug
Carpets and flooring: a rectangular rug in a standard size (or your own): its outline cut (layer 0), its border's inner edge and the binding's (or serging's) on the Border layer, a fringe at the two ends if wanted (layer 8), and an arrow showing the way the pile runs (along the rug). The border and binding are insets of the outline (OFFSET), so they follow its size.
Carpets and flooring
Round rug
Carpets and flooring: a round rug: its outline cut (layer 0), the border's inner edge and the binding's on the Border layer (insets of the outline: OFFSET, so they follow its size), and an arrow showing the way the pile runs.
Carpets and flooring
Runner with rounded ends
Carpets and flooring: a runner (a hall or stair runner) with rounded ends: its outline cut (layer 0), the ends fully round (a half circle, from two quarter circles) or with rounded corners, the border's inner edge and the binding's on the Border layer (insets of the outline: OFFSET, so they follow it), and the pile direction along it.
Carpets and flooring
Stair tread templates
Carpets and flooring: stair tread templates: a carpet piece for each step of a flight - its tread, the wrap round its nosing and its riser - one above another, numbered from the bottom; the folds at the top of the riser and the end of the nosing's wrap are marked on the Crease layer (layer 1). The bottom step can be a bullnose (its front corners rounded, as a curtail step is) with the piece wider to wrap its ends. Or the flight's carpet as one runner, each step's folds marked along it.
Foam and inserts
Bottle and vial cradle
Foam and inserts: a holder for bottles or vials standing up - round holes in a grid, or staggered (honeycomb) to fit more in - in a top sheet they go through, over a middle sheet whose holes are smaller so the bottles stand on a ledge (or a solid base); or a cradle for bottles lying down: saddles (half-round cut-outs) along a block. D is the bottle's diameter; L and W are the insert's size, and as many bottles go in as fit with the walls between them. The sheets are laid side by side to cut (layer 0).
Foam and inserts
Case insert grid
Foam and inserts: a case insert with a grid of pockets: columns and rows of rectangular pockets (their corners rounded) the walls apart and centred, each with a finger pull (a half-circle scoop) on one or both of its long sides. L and W are the insert's size (the case's inside); the pockets are POCKETW by POCKETL and DEPTH deep. The insert is built up from a top sheet the pockets go through and a solid base, laid out side by side to cut (layer 0); or one sheet, the pockets routed DEPTH deep into it (layer 3, partial depth). The depth is noted in each pocket (layer 8). Pockets of more than one size (products of two sizes, a row or column each) are given as lists of each column's pocket width (PWS) and each row's pocket length (PLS); the walls are then shared evenly between them.
Foam and inserts
Tool shadow board
Foam and inserts: a tool shadow board (a drawer or case insert): a row of tool-shaped pockets - screwdrivers (a handle and a narrower shaft), spanners (a long slot with round ends) or pliers (a wide handle and a short nose) - each with a round finger hole across its middle to lift the tool out, and a contrasting base. L and W are the board's size; the tools are spaced evenly across it, each its own length and width. The top layer's pockets are cut through (layer 0) and the base is cut beside it; each pocket's tool is named on layer 8.
Gaskets
Blind and spade plate
Gaskets: a blank plate to close off a Class 150 pipe flange (NPS ½ to 12): a blind plate to the flange's edge with the bolt holes, or a spade (slip blind) that sits inside the bolts, like a ring gasket, with a handle that stands out past the flange between two bolts, so it shows it is fitted. The size sets the flange's outside diameter, bolt circle and bolt holes (as for the Class 150 flange gasket), and the spade's diameter (centred on the bolts); the handle is kept narrow enough to pass between the bolts. A blank holds the line's pressure: its thickness and material are for the engineer. Gasket both faces.
Gaskets
Flange gasket ASME Class 150
Gaskets: a flat gasket for a pair of ASME B16.5 Class 150 pipe flanges (NPS ½ to 12): full face (to the flange's edge, with the bolt holes) or a ring inside the bolts (IBC), whose outside centres it on the bolts. The size sets the flange's outside diameter, bolt circle, number and size of bolt holes, the ring's outside diameter and the bore (the pipe's outside diameter), in mm from the usual inch sizes; the material sets the thickness and how much bigger the holes are cut (soft rubber is cut with more clearance). Check the sizes against the standard and your flanges before cutting.
Gaskets
Flange gasket EN 1092-1 PN16
Gaskets: a flat gasket for a pair of EN 1092-1 PN16 flanges: full face (to the flange's edge, with the bolt holes) or a ring inside the bolts (IBC, EN 1514-1 type). The size sets the flange's outside diameter, bolt circle, bolt holes and bore; the material sets the thickness and how much bigger the holes are cut (soft rubber is cut with more clearance). Check the sizes against the standard and your flanges before cutting.
Gaskets
Manway gasket
Gaskets: a gasket for a manway or handhole cover (a boiler, tank or vessel opening): a band of even width round an elliptical opening, or an obround one (straight sides and round ends). The sizes are the opening's (the gasket's inside); the band's outside is drawn as the true offset of the opening, so the band is the same width all round: for an ellipse with half-axes a and b, the point (a·cos t, b·sin t) moved out the band's width along the curve's normal, which points along (b·cos t, a·sin t); that curve is not itself an ellipse. The material sets the thickness. Check the opening against the cover's seat before cutting.
Gaskets
Pass partition gasket
Gaskets: a heat exchanger's channel (pass partition) gasket: a ring between the channel's flanges, with a bar across it (two passes) or a cross (four passes) that seals against the pass partition plates, so the flow is kept to its passes. The openings are the ring's inside less the bars: each is bounded by the inside circle and the bars' edges, which meet the circle at √(r² − (bar / 2)²) from the centre line. The bar is kept no wider than half the inside. The material sets the thickness. Check the sizes against the exchanger's drawing.
Gaskets
Rectangular flange gasket
Gaskets: a flat gasket for a rectangular flange (a duct, a hatch, an inspection cover, a tank's rectangular opening): a band round the opening, with bolt holes on the middle of the band, one at each corner and the rest spaced evenly along each side no more than the pitch apart. The outside corners can be rounded (the opening's corners follow, the band's width in from them). The bolt sets the holes (1 mm clearance to M10, 2 mm over); the band is made at least twice as wide as the holes, and the corner radius small enough to keep the corner holes 2 mm inside the edge. The material sets the thickness and an extra clearance for soft rubber.
Gaskets
Round gasket with bolt holes
Gaskets: a round flat gasket of any size, for a non-standard flange, a cover or a hatch: a ring with a number of bolt holes spaced evenly on a bolt circle, full face, or a ring inside the bolts. The sizes are the gasket's. The holes start half a space round from the top, so they straddle the centre lines as flange holes do. The sizes are kept in order: the bore at least 5 mm inside the holes, the outside at least 5 mm outside them. The material sets the thickness and an extra clearance on the holes and bore for soft rubber.
Gaskets
Spiral-wound gasket rings
Gaskets: the outline of a spiral-wound gasket's flat rings, for cutting the metal rings or for a drawing: the outer (centring) ring, which centres the gasket on the bolts, and the optional inner ring, which protects the winding's inside; the winding (the sealing element) sits between them and is marked, not cut. Give the sizes from the gasket maker's data for your flange: the defaults are about right for an NPS 4 Class 150 flange. The sizes are kept in order (inner ring inside the winding inside the outer ring) by at least 2 mm a side.
Glass
Glass door with hinge notches
Glass: a frameless glass door: a toughened panel with two or three hinge notches on the hinge side (rectangular, their inner corners rounded) or patch-fitting corner cut-outs, two holes for a pull handle on the other side, and a lock notch at the bottom if wanted. L is the door's width and W its height; the hinges are set from the top and the bottom (and a third midway). Holes keep at least twice the thickness from the edge. Cut on layer 0; the hinges' and handle's centre lines on layer 8.
Glass
Mirror
Glass: a mirror: rectangular (its corners square, rounded or clipped), arched at the top, oval or round, with holes to screw it to the wall if wanted, and a bevel or polished edge band marked inside its edge. L and W are its width and height (a round mirror is L across). The holes are kept at least twice the glass's thickness (and 10) from the edge, as glass needs. The mirror and its holes are cut on layer 0; the bevel's inner edge is on layer 8.
Glass
Shower screen
Glass: a fixed shower screen (a walk-in panel) of toughened glass: its top outer corner rounded, clipped or square, two wall-clamp notches or holes on the wall side, and a hole for a bracing bar near the top outer corner. L is its width and W its height. Toughened glass can't be cut or drilled after toughening, so every hole and notch is drawn now: holes at least twice the thickness (and 2.5 times from a corner) in from the edge, notches with rounded inner corners. Cut on layer 0; the clamps' centre lines on layer 8.
Glass
Splashback with sockets
Glass: a glass splashback with cut-outs for sockets and switches: a panel L wide and W high, and in it up to four cut-outs, each a single or a double socket (its size with the clearance round the box), set out from the left end and up from the bottom edge. The cut-outs' corners are rounded (glass cracks from a square inside corner) and kept at least 50 from the edges and each other, as toughened glass needs. Cut on layer 0; the boxes' centres on layer 8.
HVAC
Concentric reducer
HVAC and sheet metal: a concentric reducer (a cone frustum) developed flat: a ring segment, rolled round and closed with a lap seam. Sizes are inside diameters; the pattern is developed on the mean diameters (each the inside diameter plus the sheet's thickness T), so the rolled cone fits. The small diameter must be less than the large.
HVAC
Dovetail spigot collar
HVAC: a round spigot collar (a take-off or dovetail collar) for connecting a round duct to a rectangular duct or a plenum: a strip rolled into a short cylinder and closed with a lap seam. One end is slit into tabs: pushed through a round hole in the duct wall, every other tab is bent out against the inside of the wall and the rest bent back against the outside, locking it in. The other end is crimped (corrugated smaller) so it slides into the round duct, with a bead rolled just above the crimp as a stop. The strip's length is the mean circumference (the inside diameter plus T, times π) plus the lap; the tabs are as near the pitch asked for as fit evenly.
HVAC
Eccentric reducer
HVAC and sheet metal: an eccentric round reducer (flat on one side, so the duct's top or bottom stays level), developed flat by triangulation in one piece, rolled and closed with a lap seam along its flat side. How it is developed: the reducer is an oblique cone cut off level. Both circles are divided into the same number of equal steps; a line joins each point on the large circle to the point at the same angle on the small one (the cone's straight lines, since the circles are the same shape), and a diagonal splits each strip between two lines into two triangles. Every line's true length is worked out from the plan and the height (√(plan length² + height²)); the triangles are laid down flat one after another, each from its three true sides, sharing a side with the last. The large and small edges are curves of many short chords. Sizes are inside diameters; the pattern is developed on the mean diameters (inside plus T). The small diameter must be less than the large; the straight lines every 30° are marked on layer 8, to help the rolling.
HVAC
Lateral branch
HVAC and sheet metal: a lateral (a branch joining a main at an angle, 45° usually; 90° makes a tee), developed flat: the branch's pattern, cut to fit round the main, and the main's pattern with the hole the branch opens into. Both are round; the branch is no bigger than the main, and their axes meet. How the curves are found: a line along the branch's surface at angle φ round it runs down until it meets the main's surface. With the main along x and the branch's axis at angle α to it, that line's point at distance s along the branch is (s·cos α − r·cos φ·sin α, s·sin α + r·cos φ·cos α, r·sin φ); it is on the main where y² + z² = R², so s = (√(R² − r²·sin² φ) − r·cos φ·cos α) / sin α. Unrolled, the branch's pattern is that s plotted at each point of the stretch-out (r·φ); the hole is where each of those points lies on the main, plotted on the main's stretch-out: its x along the main, and its distance round the main (R × its angle from the top). Each curve is many short lines. The branch's seam is on its shortest line; each pattern has a seam allowance. Sizes are inside diameters; the patterns are developed on the mean diameters (inside plus T).
HVAC
Rain cap cone
HVAC: a rain cap (a "Chinese hat") for the end of a round flue or duct: a shallow cone held above the duct's end on straps, as its flat pieces: the cone and one strap (cut as many as there are legs). How the cone is developed: a cone of base radius r and rise h has a slant height s = √(r² + h²); unrolled, it is a sector of a circle of radius s, its arc as long as the base's circumference, so it spans 360° × r / s. A lap allowance on one edge closes it. Each strap runs up the duct's outside, on past its end, and is bent over to lie along the cone's underside: its length up to the bend is the gap from the duct's end to the cone's rim plus the height of the cone's underside above its rim at the duct's radius, h × (1 − rd / r). Strap lengths are to the bend line (the straps are thin). Sizes: the duct's outside diameter, the cap's diameter across its rim.
HVAC
Rectangular duct
HVAC: a straight rectangular duct section from one sheet: four panels wrapped round and closed with a Pittsburgh lock (the pocket on the first panel's edge, the male flange on the last), with an allowance at each end for the connection (slip and drive, or flanges). Panels wider than 450 can be cross-broken to stiffen them. Sizes are inside sizes: each panel is the inside size plus the sheet's thickness T. The lock and end allowances depend on your roll formers: set them to suit.
HVAC
Rectangular offset
HVAC: a rectangular offset (an ogee or S-bend) that moves a rectangular duct sideways, as its flat pieces: two cheeks (the flat sides, cut 2 alike) and two wraps (the curved sides, cut 2 alike). The cheeks' centreline is two equal arcs bending opposite ways, meeting tangent half way: for an offset O over a length L each arc turns θ = 2·atan(O/L), on a radius Rc = (L² + O²)/(4·O). Each cheek edge is the centreline moved half the width to that side, so it is an arc of Rc + W/2 then one of Rc - W/2 (or the other way round); both wraps are therefore the same length, 2·Rc·θ. The wraps carry a Pittsburgh pocket allowance on both edges, the cheeks a male flange along both curved edges, and every piece a connection allowance at each end. The offset is limited so the tighter arc keeps a sensible radius. Sizes are inside sizes; each piece is the inside size plus the sheet's thickness T.
HVAC
Rectangular radius elbow
HVAC: a rectangular radius elbow (a bend in a rectangular duct), as its flat pieces: two cheeks (the flat sides, each a ring sector, cut 2 alike) and two wraps (the curved throat and heel, each a strip as long as its arc). The wraps carry a Pittsburgh pocket allowance along both edges, the cheeks a male flange round both curved edges, as on straight duct; every piece has a connection allowance at each end. The arcs' lengths are the throat and heel radii times the angle (in radians). Sizes are inside sizes: the cheek's width is the duct's width in the plane of the bend plus the sheet's thickness T; the wraps' width is the depth plus T. Put turning vanes in an elbow whose throat radius is small for its width.
HVAC
Rectangular transition
HVAC and sheet metal: a rectangular-to-rectangular transition (a reducer), concentric or offset, developed flat in one piece, wrapped round and closed at one corner with a seam allowance, with a connection allowance along each end. How it is developed: each of the four sides is a flat trapezium (its top and bottom edges are level and parallel), but leans in two directions, so its true shape isn't seen in any view. Each side is split by a diagonal into two triangles; every edge's true length is worked out from the plan and the height (√(plan length² + height²)); the triangles are laid down flat one after another, each from its three true sides, sharing a side with the last. The corner lines between the sides are the bends, on layer 1. Sizes are inside sizes; the pattern is developed on the mean sizes (each plus the sheet's thickness T). The offsets move the top's centre from the bottom's (0, 0 for a concentric transition; half the difference in size for one side flat).
HVAC
Round end cap
HVAC: a round end cap to close the end of a round duct, in two pieces: a disc and a band. The disc's edge is turned up (on a jenny or burring machine) and seamed to the band's edge; the band either slips over the duct's plain end, or is crimped at its open end to slide into the duct like any fitting. The band's length is its mean circumference (its mean diameter times π) plus a lap; the disc is the band's mean diameter plus the turned edge all round. Sizes: D is the duct's inside diameter; a band that slips over is sized to the duct's outside (D + 2T), a crimped one is the duct's own size.
HVAC
Segmented round elbow
HVAC and sheet metal: a segmented (gored) round elbow, developed flat: the patterns for its gores, each rolled into a cylinder and joined to the next along a cut line. An elbow of N pieces has two end gores (half the angle, one end square) and N-2 middle gores, each turning the elbow through ANG/(N-1). How the cut line is found: a gore is a length of cylinder cut at each end by a plane through the elbow's centre of bend, at half the gore's angle (θ/2) either side of the gore's middle. A line along the cylinder's surface at angle φ round it (φ = 0 at the heel, the outside of the bend) lies RC + r·cos φ from the centre of bend, so it reaches (RC + r·cos φ)·tan(θ/2) to each cut plane. Unrolled, the cylinder's surface is a rectangle πd round; the cut line is that length plotted at each point of the stretch-out (s = r·φ), a curve of many short lines. The seam is put at the throat (the shortest line), with a seam allowance on one side; the end gores carry a straight collar for the connection. Sizes are inside diameters; the pattern is developed on the mean diameter (inside plus T).
HVAC
Shoe take-off
HVAC: a rectangular shoe take-off (a 45° shoe tap or boot) for a branch off a rectangular main duct, as its flat pieces: two cheeks (cut 2, one handed each way), the heel (the back panel) and the toe (the front panel, bent 45° where the lead-in starts). The lead-in turns the air into the branch: the opening on the main is longer than the branch by the lead. The heel and the toe carry a flange down each side, turned in and riveted or spot-welded to the cheeks; the toe's flanges are V-notched at its bend (45° taken out, so they close up round it) and cut square to the main at the bottom. Every piece has a row of fixing tabs along its bottom, bent out onto the main, and a connection allowance along its top for the branch duct. Sizes are inside sizes of the branch; each panel is the inside size plus the sheet's thickness T.
HVAC
Square to round transition
HVAC and sheet metal: a rectangular-to-round transition (a "square to round"), developed flat in one piece by triangulation, with the seam down the middle of one end and a seam allowance on one side. How it is developed: the fitting is four flat triangles (each with a side of the rectangle as its base and its apex where that side's plane touches the circle) and four corner cones (each fanning from a corner of the rectangle to a quarter of the circle). The quarters are divided into equal steps, and the surface into triangles between the rulings: the lines from a corner to the points on the circle. Each ruling's true length is worked out from the plan and the height (√(plan length² + height²)); the triangles are then laid down flat one after another, each from its three true sides, sharing a side with the last. The bottom edge's pieces are the rectangle's sides, the top edge's the chords of the circle. The rulings from the corners to the four tangent points are the main bends; every other ruling in the cones is marked as a light brake line, on layer 1. Sizes are inside sizes; the pattern is developed on the mean sizes (each plus the sheet's thickness T). The round can be set off-centre (an offset transition): the tangent points stay at the quarters.
Labels
Jar wrap and lid labels
Labels: a wrap-around label for a jar, tin or bottle, and a round label for its lid. The wrap is as long as the container's circumference less a gap at the back (or with an overlap, for a full wrap), and its height L sits between the shoulder and the base; the lid label is a circle a little inside the lid. D is the container's diameter and W the label's height. The labels are kiss-cut on layer 3, side by side on the liner; the liner and the label's sizes are on layer 8.
Labels
Roll labels
Labels: roll labels laid out for a rotary die: labels across the web and as many round the die cylinder's repeat as fit, the repeat being the gear's teeth times its 1/8 in (3.175 mm) pitch, so the gap around is worked out to fill it exactly. L is a label's width across the web, W its length around (a round label is L across). The labels are kiss-cut through the face material only (layer 3); the liner's edges and the repeat are on layer 8; the matrix's edge trims are cut along the web, and a wavy backing slit and perforations between rows can be added (layers 0 and 4). The web runs up the drawing.
Labels
Sheet labels
Labels: a sheet of labels for a digital press or a flatbed cutter: rows and columns of labels the gaps apart, centred on an A4, A3, Letter or SRA3 sheet (or a sheet of your own size), with registration marks at three corners for the cutter's camera. L and W are a label's width and height; as many go on the sheet as fit inside its margins. The labels are kiss-cut (layer 3) on the sheet's backing, the sheet's edge and the margins are on layer 8, and the registration marks are printed squares (layer 8).
Labels
Wine and bottle labels
Labels: a wine or bottle label in one of the classic shapes - an arched top, a shield, a rectangle with scalloped (rounded-in) corners, notched corners, or an oval - and a neck label to match if wanted, laid out on a roll: as many round the die's repeat (the gear's teeth times 1/8 in) as fit. L is the label's width (round the bottle) and W its height; the arch's rise and the corner size are kept to suit them. The labels are kiss-cut on layer 3; the liner's edges and the repeat are on layer 8.
Laser cutting
Box with sliding lid
Laser cutting: a finger-jointed box with a lid that slides in grooves along the inside of its long sides, like a pencil box. The grooves are on the Engrave layer, to engrave about half the sheet deep, near the top of each long side, on its inside face: the second side is drawn turned over so both grooves are on top as cut. The front end is lower than the back, so the lid slides in over it, and stops against the back. The lid's long edges are rebated to a tongue that runs in the grooves: the rebates are on the Engrave layer too; engrave them half deep with the lid face down. Sizes are outside sizes. The material sets the sheet's thickness (how deep the fingers are) and the laser's kerf: each finger is made wider by the kerf, and each gap narrower, so the joints are tight. Check the kerf and the engraving depth with a test cut.
Laser cutting
Cable comb
Laser cutting: a cable comb (a cable organiser) to screw under a desk or along a wall: a strip with a row of slots along one edge that the cables push into. Each slot has a round seat the size of the cable and an entry either as wide as the seat (open slots: the cables lift out) or narrower (snap-in: the cable is squeezed past the neck and held), with a chamfered mouth. The material sets the sheet's thickness and the laser's kerf: the slots are cut in by half the kerf so they come out at size. Snap-in slots suit acrylic and thin plywood that give a little.
Laser cutting
Coaster set
Laser cutting: a set of drinks coasters, round, square with rounded corners, or hexagonal, laid out in a grid on one sheet, each with a border to engrave a little in from its edge (on the Engrave layer: leave that layer out of the job for plain coasters). The size is across the coaster (a hexagon's across its flats). The material sets the laser's kerf: the outline is moved out by half of it, so the coasters come out at size.
Laser cutting
Finger-jointed box
Laser cutting: a box of five (or six, with a lid) flat panels joined with finger joints, to cut from sheet and glue or push together (the 3D page shows them put together, step by step). Sizes are outside sizes. The material sets the sheet's thickness (how deep the fingers are) and the laser's kerf (what the beam burns away): each finger is made wider by the kerf, and each gap narrower, so the joints are tight. Check the kerf with a test cut on your machine.
Laser cutting
Hexagonal planter
Laser cutting: a hexagonal (or square, five- or eight-sided) planter or lamp: a base, a ring round the top, and a side panel for each face, the sides standing between the base and the ring with two tabs at each end through slots in them. Put a pot or a liner inside, or a lamp holder through the centre hole and a shade of paper behind windows in the sides. Sizes are outside sizes: across the flats of the base and ring, and the height overall. The sides stand a sheet's thickness in from the base's edge and meet at their inside corners. The material sets the sheet's thickness and the laser's kerf: the tabs are made wider by the kerf and the slots narrower, so the joints are tight.
Laser cutting
Involute spur gear
Laser cutting: a spur gear with involute teeth, to cut from sheet, with a bore and (if wanted) a keyway. The module (the tooth size: the pitch diameter divided by the number of teeth) and the number of teeth set the gear. Two gears mesh when they have the same module and pressure angle; their centres are then half the sum of their pitch diameters apart. The teeth have the usual proportions: 1 module above the pitch circle, 1.25 below. Each flank is a true involute of the base circle, drawn as short straight lines; below the base circle it runs straight in to the root (no undercut is cut, so a gear of fewer than about 17 teeth is a little weak at the root). The material sets the thickness and the laser's kerf: the whole outline is moved out by half the kerf (the teeth a little fuller, the bore and keyway a little smaller), so the gear comes out at size. The pitch circle is marked on layer 8.
Laser cutting
Living-hinge panel
Laser cutting: a flat panel with a living hinge (a kerf-bend lattice) across its middle, so a stiff sheet can be bent round a curve: a box's rounded corner, a lamp shade, a book cover's spine. The hinge is rows of slots across the panel, each row staggered by half a slot against the next, so the strips between rows twist a little each and the band bends as a whole. The bend sets how long the band is: the angle it turns through and the inside radius, measured to the middle of the sheet (the length of the arc at R + T/2). The material sets the thickness (how close the rows are and how wide the bridges between slots are) and the kerf, which is each slot's width. Thin plywood (3 mm) bends best; MDF and acrylic crack if bent too tight: test a strip first. The ends of the band are marked on layer 8.
Laser cutting
Name sign
Laser cutting: a name sign or plaque: a panel with rounded corners, fixing or hanging holes, and a border and the name to engrave (on the Engrave layer), asked for, its letters sized to the space inside the border (a long name may need a longer sign). The material sets the laser's kerf: the outline is moved out by half of it and the holes in by half of it, so the sign and its holes come out at size.
Laser cutting
Pegboard panel
Laser cutting: a pegboard: a panel with a square grid of holes for pegs and hooks, and screw holes at the corners (and along the edges of a long board) to fix it to the wall on spacers, so the hooks have room behind it. The pitch and hole suit the usual pegboard hooks: 1 inch with 1/4 inch holes, or 25, 38 or 50 mm. The grid is centred, with a margin of at least one pitch all round. The material sets the laser's kerf: the holes are cut in by half of it and the outline out by half of it, so they come out at size.
Laser cutting
Phone stand
Laser cutting: a stand for a phone or a small tablet, of two parts that slot together at right angles: a back plate the phone leans on, and a side profile (seen from the side) that holds the plate leaning back, carries a ledge and a lip for the phone to stand on, and runs back as a strut and foot. The plate has a slot up from its bottom edge; the profile has a matching notch along the line the plate leans at, so the plate slides down into it. The ledge is wide enough for the phone's thickness (with its case) and a little play. The material sets the sheet's thickness (the slots' width) and the laser's kerf: the slots are cut narrower by the kerf, so they grip.
Laser cutting
T-slot enclosure
Laser cutting: an enclosure (a box for electronics, say) of six flat panels screwed together with T-slot joints: each edge that meets another panel has two tabs that go through slots in it, and between them a screw slot with a cross-slot (the "T") that holds a nut. The screw goes through a hole in the other panel, along the slot, and into the nut, so the box comes apart again. The front and back run between the base and the lid; the ends fit between them. Every slot and hole is kept a sheet's thickness in from an edge, so the base and lid stand out a little all round and the front and back a little past the ends. Sizes are outside sizes (the base's). The material sets the sheet's thickness and the laser's kerf: each tab is made wider by the kerf and each slot narrower, so the joints are tight; the screw slots and nut traps are cut to the screw's sizes. Check the kerf with a test cut, and the nut traps with your nuts.
Laser cutting
Tab-and-slot bookshelf
Laser cutting: a bookshelf that slots together: two sides, the shelves, and a rail across the back under the top shelf to stop it racking. Each shelf (and the rail) has two tabs at each end that go through slots in the sides; glue them, or leave them dry for a shelf that comes apart. Sizes: the shelves' length between the sides, the depth, and the height overall. The material sets the sheet's thickness (the tabs' length and the slots' width) and the laser's kerf: each tab is made wider by the kerf and each slot narrower, so the joints are tight. Check the kerf with a test cut. Shelves longer than about 600 in 6 mm sheet will sag under books.
Laser cutting
Tray with handles
Laser cutting: a serving or desk tray: a base and four low sides joined with finger joints, the two ends raised with a hand hole in each. Sizes are outside sizes; the height is the long sides', the ends stand higher by the handles. The material sets the sheet's thickness (how deep the fingers are) and the laser's kerf: each finger is made wider by the kerf, and each gap narrower, so the joints are tight. Check the kerf with a test cut.
Leather goods
Belt
Leather goods: a belt: a strap the waist size from the buckle's pin to the middle of five adjustment holes, its tip round, an English point or square with clipped corners, and at the buckle end a turn-back round the buckle with a slot for the buckle's tongue and two Chicago screw (or rivet) holes through both thicknesses; a keeper loop to go with it. L is the waist size and W the belt's width. The fold at the buckle is on layer 1, the holes and the outline on layer 0; stitch holes along both edges can be added.
Leather goods
Bifold wallet
Leather goods: a bifold wallet: the outer, folded in the middle (the fold on layer 1, with a band marked either side of it to skive thinner on layer 8), and on each side inside two card pockets, stepped one above the other, stitched to the outer along the sides and the bottom; the outer is stitched all round. L is the wallet's width folded and W its height. The stitch holes (layer 0) are as many as fit at about the irons' pitch, spaced evenly, so the pockets' holes line up with the outer's.
Leather goods
Card wallet
Leather goods: a card holder (card wallet): a back panel and a front pocket open at the top with a thumb cut-out, and a second pocket on the back if wanted, stitched together up the sides and along the bottom. L is its width and W the back's height; the pockets are 15 lower. The stitch holes are punched (or cut) on layer 0, the margin in from the edge, as many as fit at about the irons' pitch and spaced evenly, so the holes in each piece line up when they are put together. The corners are rounded; the pieces are laid out side by side.
Leather goods
Key fob
Leather goods: a key fob: a strap with round ends folded over the key ring, held by a rivet or snap through both ends, and stitched along both edges. L is the strap's length folded (from the ring to the end) and W its width; the strap is cut twice as long, the fold (layer 1) at its middle, the rivet hole through both ends (layer 0) and the stitch holes along its long edges, up to the rivet, as many as fit at about the irons' pitch. The split ring through the fold is an accessory (shown in 3D and costed by the Accessories and fitments report).
Leather goods
Tote panels
Leather goods: the panels of a leather tote: a front and a back (their bottom corners rounded), a gusset that runs down one side, along the bottom and up the other, and two handles. L is the bag's width, W its height and D its depth (the gusset's width). The panels are stitched up the sides and along the bottom, and the gusset along both edges, the holes (layer 0) as many as fit at about the irons' pitch; each handle is stitched along its edges and has two rivet holes at each end, and the handle's places are marked on the panels (layer 8).
Leather goods
Watch strap
Leather goods: a two-piece watch strap: the long piece with the holes, and the short piece with the buckle, each tapering from the lug width at the watch to the buckle width, with a fold round the spring bar at the lug end (layer 1) and stitch holes along both edges (layer 0); the short piece has a slot for the buckle's tongue at its fold, the long piece a round tip and the holes. L is the lug width and W the buckle width.
Packaging
Archive box with lid flap
An archive box (a file storage box): four panels joined by a glue flap, slotted flaps closing the bottom, and a lid hinged on the back panel that folds over the dust flaps on the ends and tucks down inside the front. Hand holes in the ends to carry it; the lid can be opened and closed again and again. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, the depth between the end creases the inside depth plus 2T, the slots 2T wide, the tuck T narrower each side than the lid and the dust flaps T short of meeting.
Packaging
Bakery box with tuck lid
A bakery (cake) box with a tuck lid: one piece, a tray whose front and back walls carry corner flaps glued inside the side walls, and a lid hinged on the back wall with dust flaps that go inside the side walls and a tuck that goes inside the front wall. A window in the lid is an option. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: the base is the inside size plus T, the walls the inside depth plus T, and the lid T short of the front wall so its tuck goes inside it, with the tuck's shoulders T in from the lid's edges.
Packaging
Bin box with hand hole
A bin box (an open-top picking or storage bin): four panels joined by a glue flap, open at the top, with slotted flaps closing the bottom. The front is cut down and the sides slope up from it to the full-height back, so the contents can be seen and picked from the front of a shelf; a hand hole in the back lets the bin be pulled out and carried. Sizes are inside sizes: L across the front, W from front to back, D the depth at the back. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, the back's height (to the bottom crease) the inside depth plus T, the front's the front height plus T, and the slots 2T wide.
Packaging
Bottle carrier with handle
A bottle carrier for 4 or 6 bottles in two rows, one blank: four walls and a glue flap with a crash-lock (auto-lock) bottom, the bottles' necks coming up through holes in the top. The front and back walls each fold in over half the top (their row of bottles), with a hole for each neck, then up at the middle, where the two meet back to back and are glued into a double handle with a hand hole through both. Sizes are inside sizes: the length holds the pack's bottles in a row (2 or 3) and the width two rows, so each is the bottles' diameter plus about 2 mm clearance times the bottles across it (the defaults suit 66 mm bottles); the depth is the inside height up to the bottles' shoulders. The board's thickness (T, chosen as the material) is allowed for: each wall is the inside size plus T, the depth between the end creases the inside depth plus 2T.
Packaging
Bottle platform insert with hole grid
A bottle platform insert: a pad of board with a grid of holes that the bottles' necks (or bodies) go through, standing on legs that fold down from its long sides (or all four), each leg with a foot that folds in under the pad so it stands steady on the case's floor. It holds bottles, jars, vials or tubes apart and upright in a case, or the necks of bottles lying in a shipper. The holes are round, or cross slits with a small relief hole that grip a neck; they go in rows and columns, or staggered (every other row moved half a pitch, one fewer in it). Sizes are the inside sizes of the case it goes in (L × W) and how high the pad stands (D). The board's thickness (T, chosen as the material) is allowed for: the pad is 2T smaller each way than the case, the corner cut-outs T wider than the legs. The holes are spread evenly over the pad, and the least wall between them is printed. Holes for bottles of more than one size (a row or column each) are given as lists of each column's and each row's cell (PS, WS: a hole is as wide as the smaller of its column's and its row's, at most HD; the pad's spare length shared evenly between the columns, its width between the rows).
Packaging
Bottle shipper partitions
Bottle shipper partitions (a slotted divider set): flat strips of board slotted half way through their height, that slide together into a grid of cells inside a shipping case, one bottle to a cell (wine, spirits, jars). Two blanks: a long partition, which runs the length of the case and is slotted from the top, and a short one, which runs across it and is slotted from the bottom; the quantities of each, and the case's inside size the set fills, are printed. Sizes are a cell's inside sizes (L × W: the bottle's diameter and a little play) and the partitions' height (D); cells of more than one size (bottles of two sizes, a row or column each) are given as lists, each column's length (PS) and each row's width (WS), as many as there are columns and rows (empty: every cell L × W). The board's thickness (T, chosen as the material) is allowed for: each partition between two cells takes T, so a partition is as long as its cells and the boards across it; the slots are 1.5T wide, centred on those boards.
Packaging
Carry carton with centre handle
A carry carton with a centre handle: four panels and a glue flap, a crash-lock (auto-lock) bottom, and a top closed by the front and back panels: each folds in over half the top, then up at the middle, where the two meet back to back and are glued into a double handle with a hand hole through both. The side panels' dust flaps fold in under the top. The bottom's front and back flaps each carry a glue tab beyond a 45° crease, glued to the side flaps with the side seam, so the carton ships flat and its bottom springs into place. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the end creases the inside depth plus 2T.
Packaging
Cereal carton with tear strip
A cereal-style seal end carton with a tear strip: four panels and a glue flap, the ends closed by glued flaps (the front and back flaps overlapping, the side flaps under them). A tear strip, two tear lines (perforated, layer 4) round the four panels just below the top, starts at a pull tab on the side panel's free edge: pulled, it opens the top without tearing the flaps. A plain top (no tear strip) can be chosen instead. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the end creases the inside depth plus 2T.
Packaging
Corner window carton
A window carton: a reverse tuck end carton with a die-cut window in the front panel, either on the front alone or wrapping round the corner onto the side panel (a corner window, the crease stopping at its edges), to be backed with film. Lids and tucks on the back panel at the top and the front panel at the bottom, dust flaps on the sides. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, the depth between the end creases the inside depth plus 2T, and the tucks' shoulders T in from the lids' edges.
Packaging
Counter display tray with header
A counter display tray with a header: one piece, a tray with a low front wall, side walls that slope up from the front wall to the back wall, and a back wall that carries on up as a header card for the graphics. The front and back walls' corner flaps are glued inside the side walls. Sizes are inside sizes: D is the back wall's height (inside), the front wall's height is chosen. The board's thickness (T, chosen as the material) is allowed for: the base is the inside size plus T, the walls their inside heights plus T.
Packaging
Crash-lock bottom box
A crash-lock bottom box (auto bottom): four panels joined by a glue flap, slotted flaps at the top like a regular slotted case, and a bottom that sets itself up as the box is opened. The two length panels' bottom flaps each carry a glue tab beyond a diagonal crease; the tabs are glued to the width panels' bottom flaps when the side seam is glued, so the box ships flat and the bottom springs into place when it is squared up. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, the depth between the flap creases the inside depth plus 2T, and the slots 2T wide.
Packaging
Crash-lock bottom carton
A crash-lock (auto-lock) bottom carton with a tuck top: four panels and a glue flap. The bottom is glued with the side seam: the front and back panels' bottom flaps each carry a glue tab beyond a 45° crease, glued to the side panels' bottom flaps, so the carton ships flat and its bottom springs into place as it is squared up. The top closes with a lid and tuck on the back panel over dust flaps on the sides; the tuck's shoulders are cut back so it catches on the dust flaps as it goes in (a friction lock). Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, the depth between the end creases the inside depth plus 2T, and the tuck's shoulders T in from the lid's edges.
Packaging
Dispenser carton with tear-off front
A dispenser carton (tissues, tea bags, gloves): a reverse tuck end carton whose front panel has a tear-off opening, a perforated tear line (layer 4) in a U from its top edge, with a thumb notch to start the tear. Torn away, it leaves the contents to be drawn out one at a time; the top lid and tuck (on the back panel) still close over it. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, the depth between the end creases the inside depth plus 2T, and the tucks' shoulders T in from the lids' edges.
Packaging
Display tray with front window
A display tray with a front window (shelf-ready tray): one piece, a tray with glued corners whose front wall is cut down between two corner posts, so the products show and can be taken from the front on the shelf. The end walls' glue flaps fold in against the side walls' corner posts and are glued to their inside faces. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: the bottom is the inside size plus T, and the walls the inside depth plus T; the corner posts are the flaps' depth plus 2T wide.
Packaging
Divider pad
A divider pad (a layer pad): a flat sheet of board laid between two layers of products in a case, or on its floor or under its top, to spread the load and keep the layers apart. Its corners can be cut off at 45° so it drops in past the case's corner joints, and it can have a lifting tab at each end that folds up, to lift it out by. Sizes are the inside sizes of the case it goes in (L × W) and the tabs' height (D). The board's thickness (T, chosen as the material) is allowed for: the pad is T smaller each way than the case, so it drops in.
Packaging
ECMA Reverse tuck end carton
A reverse tuck end carton (RTE, ECMA A20.20): four panels and a glue flap, a lid and tuck on the back panel at the top and on the front panel at the bottom, dust flaps on the sides. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the end creases the inside depth plus 2T.
Packaging
ECMA Seal end carton
A seal end carton: four panels and a glue flap, the ends closed by glued flaps: the major (front and back) flaps overlapping, the minor (side) flaps under them. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the end creases the inside depth plus 2T.
Packaging
ECMA Straight tuck end carton
A straight tuck end carton (STE, ECMA A20.20 variant): four panels and a glue flap, both lids and tucks on the back panel, so both open from the same side; dust flaps on the sides. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the end creases the inside depth plus 2T.
Packaging
FEFCO 0200 Half slotted container
FEFCO 0200: a half slotted container: a regular slotted container (0201) with no top flaps, its bottom flaps meeting in the middle. Open at the top, for a lid (a telescope lid, say) or as a tray. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the flap creases the inside depth plus 2T, so the box holds L × W × D.
Packaging
FEFCO 0201 Regular slotted container
FEFCO 0201: a regular slotted container (RSC), the everyday shipping case. Four panels joined by a glue flap, the flaps top and bottom all the same depth, the outer (length) flaps meeting in the middle. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the flap creases the inside depth plus 2T, so the box holds L × W × D.
Packaging
FEFCO 0202 Overlap slotted container
FEFCO 0202: an overlap slotted container: a regular slotted container (0201) whose outer flaps overlap by the amount given, for a stronger top and bottom. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the flap creases the inside depth plus 2T, so the box holds L × W × D.
Packaging
FEFCO 0203 Full overlap slotted container
FEFCO 0203: a full overlap slotted container (FOL): the outer flaps the full width of the box, each reaching the far side, for stacking strength and rough handling. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the flap creases the inside depth plus 2T, so the box holds L × W × D.
Packaging
FEFCO 0204 Centre special slotted container
FEFCO 0204: a centre special slotted container (CSSC): the inner flaps as well as the outer meet in the middle, so the top and the bottom are covered twice all over. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the flap creases the inside depth plus 2T, so the box holds L × W × D.
Packaging
FEFCO 0427 Mailer
FEFCO 0427: a mailer (an e-commerce or postal box): one piece, no glue. The front and the sides are double walls, rolled in over the ears of the front and back walls; the lid is hinged on the back wall, with side flaps and a tuck flap that go inside the front wall. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: the base is the inside size plus 2T (the rolled-in walls), the lid wider still, to close over the walls.
Packaging
Five-panel folder
A five-panel folder (book wrap): one piece, for long flat products such as books, frames or panels. Across the blank are five panels: a top flap, a wall, the bottom, a wall and a second top flap. The product is laid on the bottom, the ears on the walls' ends are folded in, the end walls on the bottom's ends folded up over them, then the walls and the two top flaps wrapped over, meeting in the middle or overlapping fully, and taped or glued. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, the length between the end creases the inside length plus 2T, the outer top flap T wider than the inner one (it laps over it) and the slots by the end walls 2T wide.
Packaging
Gable-top carry carton
A gable-top carry carton: four panels and a glue flap with a crash-lock (auto-lock) bottom and a pitched roof. The front and back panels fold in at the shoulders as the two roof slopes, then up at the ridge into a double handle, glued back to back, with a hand hole through both. The side panels carry on up as the gable ends, each with a flap along its sloping edges that folds in under the roof to be glued to it. The bottom's front and back flaps carry glue tabs beyond 45° creases, glued to the side flaps with the side seam, so the carton ships flat and its bottom springs into place. The roof is pitched at 45° (it rises half the width), so the fold angles set for the 3D view are right for every size: the shoulders fold 45° in, the handle 45° back up (reverse creased) at the ridge. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the end creases the inside depth plus 2T.
Packaging
Gift box with hinged lid
A gift box with a hinged lid: one piece, a tray whose front and back walls carry corner flaps glued inside the side walls, and a lid hinged on the back wall, as wide as the tray outside, with skirts that come down outside the side walls and a tuck that goes inside the front wall. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: the base is the inside size plus T, the walls the inside depth plus T; the lid is T wider each side than the base, so its skirts close over the side walls, and T short of the front wall so its tuck goes inside it, the tuck's shoulders T in from the base's edges.
Packaging
Gusset corner tray
A gusset-corner (web corner) tray: one piece, no glue or flaps to fasten. The base, four walls, and at each corner a square web folded in half on its diagonal (a reverse crease, folding 180°). As the walls go up, the web folds in against the inside of the end wall: its half on the front or back wall turns 90°, its half on the end wall 180° back flat onto it. Hand holes in the end walls are an option. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: the base is the inside size plus T, the walls (and so the webs) the inside depth plus T.
Packaging
Half slotted box with lid
A half slotted box with a separate telescope lid: two blanks. The base is a half slotted case (four panels joined by a glue flap, flaps at the bottom only, meeting in the middle); the lid is a shallow half slotted case made to slide down over the base, its flaps closing the top. The lid can be made full depth, to cover the base's walls completely (a double-walled box when closed). Sizes are the base's inside sizes. The board's thickness (T, chosen as the material) is allowed for: each base panel is the inside size plus T, and the depth between the flap creases the inside depth plus 2T; the lid's panels are 3T longer (the base's walls and T to spare), its flaps' depth 2T more than the lid depth.
Packaging
Hanging tuck end carton
A hanging tuck end carton: four panels and a glue flap, the back panel carrying on above the top as a header with a euro hang hole, for a peg or hook display. The top lid is on the front panel and tucks in behind it down the inside of the back panel; the bottom lid is on the back panel; dust flaps on the sides. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, the depth between the end creases the inside depth plus 2T, and the tucks' shoulders T in from the lids' edges.
Packaging
Hexagonal tuck end carton
A hexagonal tuck end carton: six side panels and a glue flap folded into a hexagonal tube (each crease folds 60°), closed at each end by a hexagonal lid with a tuck, over dust flaps on the four slanting panels. The top lid is on the back panel, the bottom lid on the front panel (reverse tuck), each tucking in behind the opposite panel. Sizes are inside sizes: L across the corners (end to end), W across the flats (front to back). The front and back panels are L less the slanting panels' share; when L is about 1.155 × W the hexagon is regular, longer and it is stretched. The board's thickness (T, chosen as the material) is allowed for: each panel is its inside size plus T, and the depth between the end creases the inside depth plus 2T.
Packaging
Insert pad with fold-up edges
An insert pad with fold-up edges: a flat pad of board laid in a case as a layer pad, shelf or divider, its edges creased to fold up as short walls that hold it off the case's sides and stiffen it. The edges fold up on the two long sides only (a channel, also used as a shelf divider standing on its edges), or on all four, with the corners cut away so each edge folds on its own. Sizes are the inside sizes of the case it goes in (L × W) and the edges' height (D). The board's thickness (T, chosen as the material) is allowed for: the pad is 2T smaller each way than the case (T to drop in, and the raised edges' board), and the corner cut-outs are T wider than the edges, to clear them as they fold.
Packaging
Lift-out insert pad with ribbon pulls
A lift-out insert pad with ribbon pulls: a pad of board laid in a case or a gift box over what it holds, its edges creased to fold up as short walls, with a ribbon pull near each end (a loop of ribbon through a slot) to lift it out by. The edges fold up on the two long sides only, or on all four, with the corners cut away so each edge folds on its own. The pulls are accessories: bought in (or cut from a reel), shown in 3D standing up from the pad and costed by the Accessories and fitments report from the price list; their slots are cut with the pad. Sizes are the inside sizes of the case it goes in (L × W) and the edges' height (D). The board's thickness (T, chosen as the material) is allowed for: the pad is 2T smaller each way than the case (T to drop in, and the raised edges' board), and the corner cut-outs are T wider than the edges, to clear them as they fold.
Packaging
Matchbox drawer and sleeve
A matchbox (slide box): a drawer, a tray with glued corner flaps, and a sleeve it slides into, four panels and a glue flap, open at both ends. The sleeve is beside the drawer. Sizes are the drawer's inside sizes. The board's thickness (T, chosen as the material) is allowed for: the drawer's base is the inside size plus T, and the sleeve fits round the drawer with T to spare.
Packaging
Pillow box
A pillow box: two panels and a glue flap, the ends curved, cut convex and creased concave, pressed in to close. Its thickness, D, sets how deep the curves are. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside width plus T, the length the inside length plus 2T.
Packaging
Pizza box
A pizza box: one piece of corrugated board (E or B flute usually), no glue. The front and the sides are double walls, rolled in over the ears of the front and back walls, their locking tabs pushed into slots in the bottom; the lid is hinged on the back wall and closes flat over the rolled walls, its tuck going down inside the front wall. A thumb notch in the front's top fold helps to open it, and steam vents in the lid near the hinge let the moisture out. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: the base is the inside size plus 2T (the rolled-in walls), the lid wider by T each side, to close over the side walls; the slots are T wider than their tabs and the tabs T long (the bottom's thickness).
Packaging
Pyramid carton
A pyramid carton: one piece, a base and four triangular sides that fold up to meet at the apex, the front and back triangles carrying glue flaps along their sloping edges, glued inside the left and right ones (or the back pair tucked in, not glued, to open it). Sizes are inside sizes: L × W the base, D the height to the apex. The board's thickness (T, chosen as the material) is allowed for: the base is the inside size plus T, the height the inside height plus T. The folds are worked out from the sizes, so the 3D view closes the pyramid whatever its proportions: each side folds up from the base 180° less its slope, and each glue flap folds onto the next side by the angle between the two sides' faces, and 1.5° more so it lies just inside it (120° and 77° for the default sizes).
Packaging
Retail sleeve with hang tab
A retail sleeve with a hang tab: four panels and a glue flap, open at both ends, to slide over a tray or a product. The back panel carries on above the top end as a header with a euro hang hole (a slot with a round hole above it), and the front panel has thumb notches at its ends to push the contents out. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the sleeve's length the inside depth plus 2T.
Packaging
Roll-end tuck-front mailer
A roll-end tuck-front mailer for e-commerce: one piece, no glue or tape. The front and the sides are double walls, rolled in over the ears of the front and back walls; each rolled-in wall has two locking tabs on its free edge that push into slots in the bottom, so the walls stay down while the box is packed. The lid is hinged on the back wall, with dust flaps at its sides and a tuck that goes inside the front wall; a thumb notch in the front's top fold helps to open it. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: the base is the inside size plus 2T (the rolled-in walls), the lid wider still, to close over the walls; the slots are T wider than their tabs and the tabs T long (the bottom's thickness).
Packaging
Self-locking tray
A self-locking tray: one piece, set up by hand with no glue, tape or staples. The side walls carry ears at their ends; the ears are folded in, then the double end walls are rolled over them, and the rolled-in walls' locking tabs pushed into slots in the bottom, trapping the ears and locking the corners. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: the bottom is the inside width plus T, and the inside length plus 5T (each end wall is rolled over two creases 2T apart, the ears trapped between its walls); the rolled-in walls are 2T lower than the outer ones, to clear the bottom; the slots are T wider than their tabs and the tabs T long (the bottom's thickness).
Packaging
Shipping case with carry handle
A shipping case with a carry handle: a regular slotted container (FEFCO 0201) with a plastic carry handle clipped through two slots in one of its outer top flaps, to carry it closed (bottles, paint, groceries, a gift hamper). The handle is an accessory: it is bought in, shown in 3D on the closed case and costed by the Accessories and fitments report from the price list. Its slots are cut with the case; its span (between the slots) is kept inside the flap. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the flap creases the inside depth plus 2T, so the box holds L × W × D.
Packaging
Sleeve
A sleeve (a wrap): four panels and a glue flap, open at both ends, to slide over a tray or a product. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the end creases the inside depth plus 2T.
Packaging
Snap-lock bottom box
A snap-lock bottom box (1-2-3 bottom): four panels joined by a glue flap, with a bottom closed by hand without tape or glue. The width panels' bottom flaps fold in first, then the front flap with its notch, then the back flap, whose tongue is pushed home into the notch to lock the bottom. The top is a tuck lid hinged on the front panel with dust flaps on the width panels, or slotted flaps as on a regular slotted case. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, the depth between the end creases the inside depth plus 2T, the slots 2T wide and the tongue 2T narrower than its notch.
Packaging
Snap-lock bottom carton
A snap-lock (1-2-3) bottom carton with a tuck top: four panels and a glue flap. The bottom is closed by hand with no glue: the side panels' flaps fold in first, then the back flap, whose tongue snaps into the notch in the front flap as it goes in last, locking the four flaps together. The top closes with a lid and tuck on the back panel over dust flaps on the sides; the tuck's shoulders are cut back so it catches on the dust flaps as it goes in (a friction lock). Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, the depth between the end creases the inside depth plus 2T, the notch 2T wider than the tongue and the tuck's shoulders T in from the lid's edges.
Packaging
Telescope base and lid
A telescope box: a base and a lid, each a tray with glued (or stapled) corner flaps, the lid made to slide over the base (FEFCO 0300 series). Sizes are inside sizes of the base. The board's thickness (T, chosen as the material) is allowed for: the base is the inside size plus T, and the lid fits over the base's walls with T to spare.
Packaging
Tray with glued corners
A tray with glued corners (four-corner tray): one piece, the bottom with a wall on each side. Each end wall has a glue flap at both ends; as the walls are raised the flaps fold in against the side walls and are glued to their inside faces, so the tray's outside is clean and the corners square. Used for produce, bakery and shelf trays, or as the base of a telescope box. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: the bottom is the inside size plus T, and the walls the inside depth plus T; the flaps are tapered at both ends to clear the corners.
Packaging
Triangular prism carton
A triangular prism carton (a bar carton, like a chocolate bar's): three panels and a glue flap folded into a triangular tube, a base panel and two sloping sides; each end closed by a triangle hinged on the base panel, with tuck flaps on its sloping edges that go in against the sides. Sizes are inside sizes: L the bar's length (end to end), W the triangle's base, D its height; an equilateral triangle has D about 0.866 × W. The board's thickness (T, chosen as the material) is allowed for: the base and the triangle's height are the inside sizes plus T, the sides as long as the triangle needs them, and the length between the end creases the inside length plus 2T. The tube's creases fold as far as the triangle's corners need, worked out from W and D (120° each for an equilateral triangle), so the 3D view closes the tube whatever its shape.
Packaging
Wallet folder with tuck flap
A wallet folder with a tuck flap (a CD, card or leaflet wallet): one piece, no glue. A back panel with low walls on three sides, a spine as deep as the walls, and a front cover whose tuck flap goes down inside the wall opposite the spine. The walls' ends are tapered to clear each other. Sizes are inside sizes: L across (spine to tuck), W up the spine, D the wallet's thickness. The board's thickness (T, chosen as the material) is allowed for: the back is the inside size plus T, the spine D plus T, the cover T short of the far wall so its tuck goes inside it, the tuck T in from the cover's edges.
Packaging
Window carton with film and hang tab
A window carton with film and a hang tab: a straight tuck end carton (both tucks on the back panel) with a window in its front panel, a clear PET film glued behind the window, and a self-adhesive plastic euro hang tab on the back panel standing up past the top, to hang the carton on a peg. The film and the tab are accessories: they are bought in, shown in 3D (the film inside, the tab outside) and costed by the Accessories and fitments report from the price list. The film is the window's size and its overlap all round. Sizes are inside sizes. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, and the depth between the end creases the inside depth plus 2T.
Packaging
Wrap-around case
A wrap-around case: a one-piece blank folded round the product on the packing line. The product is set on the bottom panel, the walls and the top are wrapped up and over it, and the glue flap on the top's edge is glued to the outside of the front wall; the end flaps then close the ends (the walls' flaps first, then the bottom's and top's, meeting in the middle of each end). Sizes are inside sizes: L the length (along the seam), W the width, D the depth. The board's thickness (T, chosen as the material) is allowed for: each panel is the inside size plus T, the length between the end creases the inside length plus 2T, and the slots between the end flaps 2T wide.
Picture framing
Double mount
Picture framing: a double mount sized from the picture: the under mount's aperture is the picture less its overlap each side (so the picture's edges stay hidden), and the top mount's aperture is bigger than that by the reveal each side, so a band of the under mount shows round the picture. Both boards are the same outside size: the top mount's borders round its aperture (the sides and top the same, the bottom heavier by the bottom weighting). Each is drawn: the outside and the aperture cut (layer 0), the bevel line in by the bevel's width on the Bevel layer (20), and on the top mount a V-groove if you want one (layer 6).
Picture framing
Frame moulding cut list
Picture framing: the cut list for a frame: the four pieces of moulding, mitred at 45°, laid out flat with their outside (long-point) lengths written on them. The rebate size is the picture (with its mount, if it has one) and the rebate allowance; each piece's cut length, long point to long point, is the rebate size and twice the moulding's width less its rebate: cut length = picture + allowance + 2 × (moulding width − rebate). The sight size (the opening the front shows) is the rebate size less the rebate each side. The pieces are cut (layer 0); the rebate line, the lengths and the total moulding to buy (with a saw cut a piece and 10 % spare) on layer 8.
Picture framing
Glass and backing board
Picture framing: the glass (or acrylic), the backing board and the mount blank for a frame, from its rebate size (measured inside the rebate): each a little smaller than the rebate, by the clearance all round, so they drop in. The backing board has the hanging fittings' screw holes marked: two D-rings a third of the way down, in from the sides, and the turn buttons or points round the edge that hold the backing in. The sheets are cut (layer 0); the marks and labels are on layer 8. The fittings - the D-rings, the hanging wire between them and two wall bumpers at the bottom corners - are accessories, on the backing (shown in 3D and costed by the Accessories and fitments report).
Picture framing
Oval and circle mount
Picture framing: a mount with an oval or a round aperture: centred across the board, and above the middle by half the bottom weighting, so the margin below is heavier, as with a rectangular window. The outside is cut straight and the aperture with a 45° bevel (layer 0); the bevel line, the aperture's true offset in by the bevel's width, is on the Bevel layer (20), and a V-groove the same distance outside it all round on layer 6.
Picture framing
Window mount
Picture framing: a window mount (a mat, a passe-partout): a board the frame's rebate size with one aperture, or a grid of them (rows × columns), the apertures filling what the margins leave: the same margin at the sides and the top, the bottom margin heavier by the bottom weighting so the pictures sit a little above the middle. The outside is cut straight and the apertures with a 45° bevel (layer 0); the bevel lines, in from each aperture by the bevel's width (the board's thickness at 45°: where the bevel meets the back), are on the Bevel layer (20). A V-groove round each aperture, a set distance outside it, is on layer 6 (V-cut).
Pipework
Branch hole template
Pipework: a wrap-round template for marking the hole to cut in a main pipe for a branch, square or at an angle, on the main's centre line or offset to one side. Print it full size and wrap it round the main, the edges meeting underneath; mark round the hole. For a set-on branch the hole is the branch's bore (the branch sits on the main); for a set-in (set-through) branch it is the branch's outside. The pipes are chosen with a typical wall (check yours). Worked out on the main's outside: with the main's axis along X and the branch's at the angle B to it, a line of the hole's cylinder at an angle θ round it is at y = E + r·sin θ across the main and meets its surface at the height z = √(R² − y²), at x = z·cot B − r·cos θ / sin B along the main. Unrolled, the hole's point is R·asin(y / R) round the main (from its top) and x along it.
Pipework
Branch on a reducer template
Pipework: a wrap-round template for cutting a branch pipe to sit on a concentric reducer (a cone), square to the reducer's axis, its centre line through the axis. Print it full size, wrap it round the branch and mark along the curve. Worked out on the outside diameters: the cone's radius falls evenly from R1 at its large end to R2 at its small end over its length, ρ(x) = R1 − (R1 − R2)·x / length. A line along the branch at an angle θ round it (θ = 0 towards the small end) is at x = c + r·cos θ along the cone and r·sin θ to the side, so it meets the cone at the height √(ρ(x)² − (r·sin θ)²); the curve is that less ρ(c), the cone's radius under the branch's centre. The branch is kept no bigger than the small end and wholly on the cone.
Pipework
Branch saddle template
Pipework: a wrap-round template for cutting a branch pipe to sit on a main pipe at 90° (a set-on branch, the "fish mouth"). Print it full size, wrap it round the branch, and mark along the curve. The pipes are chosen by material and size, which sets their outside diameters; the branch must be no bigger than the main.
Pipework
Insulation jacket wrap
Pipework: the flat sheet for a straight insulation jacket (cladding): a sheet wrapped round the insulated pipe and lapped along its length, with an optional row of pre-drilled fixing holes along the lap (for screws or rivets) and a lap at one end to go over the next sheet. The sheet's width is the circumference on its mean diameter (the pipe's outside, twice the insulation, and the sheet's thickness T) plus the side lap. L is the length of pipe the sheet covers.
Pipework
Lateral branch template
Pipework: a wrap-round template for cutting a branch pipe to sit on a main pipe at an angle (a lateral, such as a 45° Y), the axes meeting. Print it full size, wrap it round the branch and mark along the curve. Worked out on the outside diameters: with the main's axis along X and the branch's axis at the angle B to it, a line along the branch at an angle θ round it (θ = 0 on the heel, the side away from the lean; 180° in the crotch) is r·sin θ to the side of the main's axis and r·cos θ·cos B above the branch's axis, so it meets the main's surface at the height √(R² − (r·sin θ)²), a distance s = (√(R² − (r·sin θ)²) − r·cos θ·cos B) / sin B along the branch. The curve is s less the distance R / sin B where the centre line meets the main. L is the branch's length on its centre line from there. The branch must be no bigger than the main.
Pipework
Lobster-back bend segments
Pipework: wrap-round templates for a lobster-back (segmented) bend: the middle segments, cut both ends, and the two end segments, square at one end. A bend of BEND degrees with M middle segments has M + 1 joints, each turning BEND/(M + 1), so every cut is a = BEND/(2(M + 1)) off square. On the bend's radius RB (to the centre line) a middle segment is 2·RB·tan a long on its centre line; on the line along the pipe at an angle θ round it (from the back of the bend) each cut is (RB + R·cos θ)·tan a from the segment's middle, R being the outside radius, so the back is longest and the throat shortest. An end segment has the straight S added at its square end. Print full size, wrap round the pipe and mark; cut M middle segments and 2 end segments.
Pipework
Mitre cut template
Pipework: a wrap-round template for the cut of a mitred bend. A bend of BEND degrees made with J joints turns BEND/J at each joint, so each cut is BEND/(2J) off square: a two-piece 90° mitre is cut at 45°. Print it full size, wrap it round the pipe with the straight edge square to the pipe, and mark along the curve; the same template marks every cut of the bend. The cut is a plane through the pipe: on the line along the pipe at an angle θ round it (from the back of the bend), the plane is R·tan(cut)·cos θ beyond where it crosses the centre line, R being the outside radius, so the curve is drawn on the outside diameter, where it is marked. L is the length of the piece on its centre line, from the square end to the cut.
Pipework
Offset branch template
Pipework: a wrap-round template for cutting a branch pipe to sit square (at 90°) on a main pipe with its centre line offset to one side of the main's (an eccentric or tangential branch; at the largest offset the branch is flush with the main's side). Print it full size, wrap it round the branch and mark along the curve. Worked out on the outside diameters: a line along the branch at an angle θ round it is E + r·sin θ to the side of the main's axis, so it meets the main at the height √(R² − (E + r·sin θ)²); the curve is that less the height √(R² − E²) where the branch's centre line meets it. L is the branch's length on its centre line from there. The offset is kept within R − r, so the branch stays on the main.
Pipework
Tube to plate at an angle
Pipework: a tube or pipe set on a flat plate (a base plate, a flange face, a wall) at an angle: a wrap-round template for the tube's end, and the oval it stands on, to mark on the plate (or cut, for a tube that passes through). Print it full size, wrap the template round the tube and mark along the curve. Worked out on the outside diameter: with the tube's axis at the angle B to the plate, a line along the tube at an angle θ round it (θ = 0 on the side leaning away from the plate, the long side) is r·cos θ·cos B above the axis, so it meets the plate a distance r·cos θ·cos B / sin B before the centre line does. The footprint is an ellipse, r / sin B by r. L is the tube's length on its centre line from the plate.
Sewing
Baby bib
Sewing: a baby bib that fastens with a snap: a round body with a band round the neck whose two ends, rounded, lap over each other at the back of the neck. The neck hole's radius is set so that, with the snaps' centres together, the neck edge is the neck measurement and 20 of ease long; the ends stand a little apart in the flat. L is the body's width (its diameter), D the bib's length from the top of the band to the bottom. Cut a front in cotton and a back in towelling, sew them together round the edge (leave a gap at the side to turn it through), turn and topstitch, and fix a snap at each marked point (one facing up, one down). The fabric sets the seam allowance: the cutting line allows for it, the sewing line is dashed on layer 4, labels, snaps and the grain line on layer 8.
Sewing
Bib apron
Sewing: a bib apron: the apron in one piece, its bib joined to the skirt by curved armholes, with a neck strap, two waist ties and an optional patch pocket. L is the skirt's width, D the apron's length from the top of the bib to the hem, W the bib's width; the bib height is measured from the waist up. Every edge of the apron is finished with a double-turned hem: the cutting line is a hem's width outside the finished edge (the fold), the stitching is half a hem inside it. The straps and ties are folded in four. The fabric sets the seam allowance and the hem: the sewing lines are dashed on layer 4, the folds on layer 1, the labels and grain lines on layer 8.
Sewing
Bucket hat
Sewing: a lined bucket hat: a round crown, a side band and a sloping brim, each cut in the outer fabric and again in the lining. The head measurement (with a little ease) sets the head line; the side band leans in towards a smaller crown, so it is cut as a ring segment: a cone opened out, its radius the band's slant times the head radius over how far it leans in. The brim slopes down at the angle chosen: it is a cone too, cut as two half rings whose inner radius is the head radius over the cosine of the slope, joined at the sides. The fabric sets the seam allowance: the cutting lines allow for it, the sewing lines are dashed on layer 4 (with rows of topstitching round the brim), the labels and grain lines on layer 8.
Sewing
Bunting
Sewing: bunting: pennant flags, each two triangles sewn together down their sloping sides and turned out, their tops enclosed in a folded bias tape that runs the length of the string with ties at the ends. L is a flag's finished width across the top, D its depth to the point. The cutting line is a seam allowance outside the sloping sides (out at the point by the allowance over the sine of half the point's angle, and along the top by the allowance over its cosine); the top is cut on the finished line, the tape covering it. The fabric sets the seam allowance: the sewing lines are dashed on layer 4, the tape's line on layer 1, the labels and grain lines on layer 8. The number of flags, their spacing and the ties set the tape's length, printed.
Sewing
Circle skirt
Sewing: a circle skirt: a ring of fabric whose inner edge is the waist, as a full circle (two half circles, sewn at both sides), a half circle or a quarter circle (one piece, sewn at the back), with a straight waistband. The waist line's radius is the waist measurement divided by 2π times the part of a circle the skirt makes (r = waist / 2π for a full circle, waist / π for a half, 2 × waist / π for a quarter); the hem is the skirt's length further out. The fabric sets the seam allowance and the narrow double-turned hem: the cutting lines allow for them, the sewing lines are dashed on layer 4, the folds on layer 1, the labels and grain lines on layer 8. Leave the top of one seam open for a zip.
Sewing
Drawstring bag
Sewing: a drawstring bag: two body pieces sewn round the sides and bottom, with boxed corners for a flat base (a base depth of 0 gives a flat bag). The top is turned under and folded down to make a casing for the cord; the side seams stop at the casing so two cords can be threaded from opposite sides and pulled both ways. L and D are the bag's finished width and height, W the depth of its base, the casing the channel's width. The fabric sets the seam allowance and the turn-under at the top: the cutting lines allow for them, the sewing lines are dashed on layer 4, the folds on layer 1, the labels and grain lines on layer 8. The cords are an accessory (shown in 3D and costed by the Accessories and fitments report): two, each round the whole top.
Sewing
Duffle bag
Sewing: a cylinder duffle bag: two round ends and a body wrapped round them, its long edges sewn to a zip along the top, with two carry handles or a shoulder strap. D is the ends' finished diameter, L the bag's finished length. The body's width is the ends' circumference (π × the diameter) less the zip's exposed teeth, so it fits the ends exactly; quarter marks on the ends and the body line them up. The fabric sets the seam allowance: the cutting lines allow for it, the sewing lines are dashed on layer 4, the folds on layer 1, the labels, match marks and grain lines on layer 8.
Sewing
Elastic waist skirt
Sewing: a gathered skirt with an elastic waist, from two rectangles (front and back) sewn at the sides. Each panel is half the hip measurement times the fullness wide (never less than the hips and 100 of ease, so it pulls on); the top is turned under and folded down into a casing for the elastic, the bottom double-turned for the hem. D is the finished length from the waist's top edge to the hem. The elastic is cut 10% shorter than the waist, with 20 to overlap. The fabric sets the seam allowance and the hem: the cutting lines allow for them, the sewing lines are dashed on layer 4, the folds on layer 1, the labels and grain lines on layer 8.
Sewing
Envelope cushion cover
Sewing: an envelope cushion cover: a front and two back pieces whose hemmed edges overlap across the middle of the back, so the cushion pad slips in without a zip or buttons. L and D are the cushion pad's width and height; the fit makes the cover a little smaller than the pad for a plump cushion, or the same size. The overlap is how far the two backs lap over each other. The fabric sets the seam allowance and the backs' double-turned hem: the cutting lines allow for them, the sewing lines are dashed on layer 4, the folds on layer 1, the labels and grain lines on layer 8.
Sewing
Fabric storage basket
Sewing: a lined fabric storage basket: an outer and a lining, each two pieces with boxed corners (the squares cut from the bottom corners make the base when they are sewn), sewn together round the top and turned through a gap left in the lining's bottom seam; the top can be folded down outside as a cuff, and loop handles sewn into the side seams. L, W and D are the basket's finished length, width and height (to the fold at the top). Stiffen the outer with fusible foam or fleece cut to the sewing lines. The fabric sets the seam allowance: the cutting lines allow for it, the sewing lines are dashed on layer 4, the folds on layer 1, the labels and grain lines on layer 8.
Sewing
Housewife pillowcase
Sewing: a housewife pillowcase in one piece: the back, the front and the flap that tucks inside to hold the pillow in, laid out along the fabric's length. The back's open end is hemmed, the piece is folded at the closed end, the flap is folded back over the back's hem, and both sides are sewn through all the layers in one go. L and W are the pillow's length and width (the case is cut with a little ease); the flap is how far it tucks in. The fabric sets the seam allowance and the hems: the cutting lines allow for them, the sewing lines are dashed on layer 4, the folds on layer 1, the labels and grain lines on layer 8.
Sewing
Infinity scarf
Sewing: an infinity scarf (snood): one long strip whose ends are joined into a loop. As a tube, the strip is folded in half along its length, sewn into a tube, and its ends sewn together (with a half twist for a Möbius loop if wished), leaving a gap to close by hand; as a single layer, its long edges are double-turned hems and the ends joined with a seam. L is the loop's finished length round, W the scarf's finished width. The fabric sets the seam allowance and the hem: the cutting lines allow for them, the sewing lines are dashed on layer 4, the folds on layer 1, the labels and grain lines on layer 8.
Sewing
Oven mitt
Sewing: a quilted oven mitt: a mitten with a rounded top and a thumb angled off one side, cut in the outer fabric, the lining and heat-resistant wadding (two of each, one turned over), with a hanging loop and a bias binding round the cuff. L is the palm's finished width, D the mitt's length from the cuff to the top; the thumb is worked out from them (its width 0.42 of the palm's, its crotch 0.45 of the length up, its inner edge 0.36 of the length long, leaning out at 15°), and runs straight down to the cuff. The cutting line is a seam allowance outside the sewing line everywhere but the cuff, which is cut on the finished line and bound. The fabric sets the seam allowance: the sewing lines are dashed on layer 4, the folds on layer 1, the labels and grain lines on layer 8.
Sewing
Placemat and napkin set
Sewing: a placemat and napkin set. The placemat is a front and a back sewn together round the edge, turned out through a gap left in one side and topstitched; the napkin is a single layer with a double-turned hem and mitred corners (fold each corner in on the diagonal through the finished corner before turning the hem). L and W are the placemat's finished size, the napkin's size is its finished square. The fabric sets the seam allowance and the napkin's hem: the cutting lines allow for them, the sewing lines are dashed on layer 4, the folds on layer 1, the labels and grain lines on layer 8.
Sewing
Tote bag
Sewing: a tote bag: two body pieces with boxed corners (the squares cut from the bottom corners make the gusset when they are sewn), and two handles folded in four. The fabric sets the seam allowance and the top hem: the cutting lines allow for them, the sewing lines are dashed on layer 4, the folds on layer 1, the labels on layer 8.
Sewing
Zip pouch
Sewing: a lined zip pouch or pencil case: an outer and a lining piece each side, sewn to a zip along the top, with boxed corners for a flat base (a base depth of 0 gives a flat pouch), and optional tabs to cover the zip's ends. L and D are the pouch's finished width (along the zip) and height, W the depth of its base. The fabric sets the seam allowance: the cutting lines allow for it, the sewing lines are dashed on layer 4, the folds on layer 1, the labels and grain lines on layer 8. Use a zip at least as long as printed.
Sheet metal
Angle bracket
Sheet metal: an angle bracket, one 90° bend, with fixing holes in each leg. Sizes are outside sizes. The flat blank allows for the bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R (BA = π/2 × (R + K × T)), each leg the outside size less the set-back (R + T). The K-factors are typical for air bending: check them against your press brake.
Sheet metal
Cable tray section
Sheet metal: a straight section of perforated cable tray, bent from one flat strip: a base, a side up each edge, and a lip turned in along the top of each side to stiffen it (four 90° bends, all the same way). The base is perforated with slots across it, for ventilation and for cable ties; each side has a pair of holes at each end for the couplers that join one length to the next. Sizes are outside sizes. The flat blank allows for each bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R (BA = π/2 × (R + K × T)), each flat the outside size less the set-back (R + T) at each of its bends.
Sheet metal
Corner gusset
Sheet metal and fabrication: a corner gusset (a triangular stiffener plate) for the inside of a right-angled joint. The square corner is sniped (cut off at 45°) to clear the weld or the root radius of the joint it sits in, and the two sharp tips are cut square. Options: a lightening hole in the middle, and a flange bent along the long edge to stiffen a thin gusset; the flat blank then allows for the bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R (BA = π/2 × (R + K × T)), the flange's flat its outside height less the set-back (R + T).
Sheet metal
Electrical junction box
Sheet metal: an electrical junction box (an adaptable box) bent up from one flat blank: a base, four sides, and a return flange along the top of each long side for the lid's screws. The sides carry cable-entry knockouts: each a round cut held in by small uncut bridges, knocked out on site where a gland is wanted. The base has four fixing holes. Sizes are outside sizes. The flat blank allows for each bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R (BA = π/2 × (R + K × T)), each flat the outside size less the set-back (R + T) at each bend. The end sides are one thickness lower so the return flanges sit on them; the corners are cut away to relieve the bends, to be welded or sealed.
Sheet metal
Enclosure tray
Sheet metal: a tray (an open box) bent up from one flat blank: a base and four flanges, the corners relieved. Sizes are outside sizes. The flat blank allows for each bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R (BA = π/2 × (R + K × T)), the flat parts the outside sizes less the set-back (R + T) at each bend. The K-factors are typical for air bending: check them against your press brake.
Sheet metal
Equipment chassis with return flanges
Sheet metal: an equipment chassis (a pan) bent up from one flat blank: a base, four sides, and a return flange turned in along the top of every side, to stiffen it and to take the cover's screws. The return flanges' ends are mitred at 45° (less a small gap) so they meet at the corners; the corners of the blank are cut away to relieve the base's bends. Sizes are outside sizes. The flat blank allows for each bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R (BA = π/2 × (R + K × T)), each flat the outside size less the set-back (R + T) at each of its bends. All the bends go the same way. The K-factors are typical for air bending: check them against your press brake.
Sheet metal
Hat section rail
Sheet metal: a hat section (a top-hat rail or furring channel): a raised top, two webs, and a flange out at each side, four 90° bends in all; the flanges have an optional row of fixing holes. Sizes are outside sizes: the top's width and the height overall across the outside faces, each flange from its edge to the web's outside face. The flat blank allows for each bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R (BA = π/2 × (R + K × T)), each flat the outside size less the set-back (R + T) at each of its bends. The outer two bends go up and the inner two down (marked), so the top stands proud of the flanges.
Sheet metal
Hemmed edge panel
Sheet metal: a flat panel with hemmed edges: each hemmed edge folded right back on itself (180°), to stiffen it and leave no raw edge. A closed hem is pressed flat; an open (teardrop) hem keeps a gap of one thickness inside. Sizes are finished sizes: the panel to the hems' folded edges, the hem's width from its fold to its edge. The hem allowance is worked out like any bend's: the bend allowance for 180° from the material's K-factor, its thickness T and the inside radius R (BA = π × (R + K × T), R = 0 for a closed hem, T/2 for an open one), plus the hem's flat (its width less the set-back R + T). Where two hems meet, their ends are mitred at 45° with a small gap so they lie side by side when folded.
Sheet metal
Mounting plate with slotted holes
Sheet metal: a flat mounting plate (a base plate or adaptor plate) with a slotted hole near each corner, so it can be adjusted when fixed, and an optional pattern of holes in the middle for the equipment mounted on it. The slots run along the plate's length or across it; the corners can be rounded. With "Folded edges" the plate gets a stiffening flange down each long side: the flat blank then allows for the bends (BA = π/2 × (R + K × T), each flat the outside size less the set-back R + T). Sizes are outside sizes.
Sheet metal
Open box with corner tabs
Sheet metal: an open box bent up from one flat blank: a base, four sides, and a tab at each end of the two long sides that bends round the corner and laps outside the end side, to be riveted, spot-welded or screwed. The corners are notched to relieve the bends. Sizes are outside sizes of the box (the tabs add one thickness at the corners). The flat blank allows for each bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R (BA = π/2 × (R + K × T)), each flat the outside size less the set-back (R + T) at each bend. Each long side runs on by T past the base so that its tab bends round the end side's outside face. The K-factors are typical for air bending: check them against your press brake.
Sheet metal
Shelf bracket with gusset flanges
Sheet metal: a shelf bracket: a wall leg and a shelf leg at 90°, stiffened by a tapered flange along each side of the shelf leg, bent down into the angle as a gusset: deep at the wall, shallow at the tip. Each side flange starts a little way along the shelf, past the main bend, so the bends don't meet (the bend relief); bent, it stands just clear of the wall leg. Sizes are outside sizes. The flat blank allows for each bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R (BA = π/2 × (R + K × T)), each flat the outside size less the set-back (R + T) at each bend. All three bends go the same way.
Sheet metal
U channel
Sheet metal: a U channel, two 90° bends the same way, with an optional row of fixing holes along the base. Sizes are outside sizes. The flat blank allows for each bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R (BA = π/2 × (R + K × T)), each flat the outside size less the set-back (R + T) at each of its bends. The K-factors are typical for air bending: check them against your press brake.
Sheet metal
Vent panel with slots
Sheet metal: a ventilation panel: a field of round-ended slots in rows, straight or staggered, inside a plain border, with a fixing hole in each corner. It can be flat, or flanged all round (a 90° flange on each edge, the corners cut away to relieve the bends) to stiffen it and stand it off the panel it covers. Sizes are outside sizes. The flanged blank allows for each bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R = T (BA = π/2 × (R + K × T)), each flat the outside size less the set-back (R + T). The rows of slots are as many as fit the border; the open area is printed.
Sheet metal
Z bracket
Sheet metal: a Z bracket (a joggle): two 90° bends in opposite directions, the first bent up and the second bent down, with an optional row of fixing holes in each flange. Sizes are outside sizes: each flange from its end to the web's outside face, the web's height overall. The flat blank allows for each bend: the bend allowance from the material's K-factor, its thickness T and the inside bend radius R (BA = π/2 × (R + K × T)), each flat the outside size less the set-back (R + T) at each of its bends. The bend lines are marked UP and DOWN.
Sign making
A-board panels
Sign making: the two panels of an A-board (a sandwich board, a pavement sign): each the board's width and height, with a hand hole near the top to carry it by, the hinges' screw holes along the top edge, and a hole each side for the stay (a chain or a folding strut) that stops the legs spreading too far; the stay's length for the angle the board opens to is printed. The window of a poster or chalkboard insert, in by its border, is marked on layer 8. Everything else is cut (layer 0).
Sign making
Hanging sign with bracket holes
Sign making: a hanging or projecting sign: a panel hung below a projecting bracket from two holes along its top edge (the bracket's hooks or eyes, at its spacing), or fixed flat to a flag bracket through two holes along its wall side; and beside it the bracket's wall plate as a drilling template with its four fixing holes. A double-sided sign is two panels back to back, both drawn. The panels, holes and template are cut (layer 0); the panel's centre line and the template's label are on layer 8.
Sign making
Plaque with routed border
Sign making: a letter plate or plaque - rectangular, rounded, oval or with cut corners - with a border routed (or V-carved) a set distance in from its edge, following its shape, one line or two, and the wording to engrave inside it, its letters sized to the space. The border and the wording are on the Route layer (21: set its router or engraving tool and depth); the outline is cut (layer 0). Fix it with screw holes and caps in the corners, or with studs on the back, marked on layer 8 for drilling the back.
Sign making
Shaped sign blank
Sign making: a shaped sign blank in one of the shapes road and safety signs use - a circle, a triangle point up or down, an octagon, a diamond or a square - with rounded corners, a border line a set distance in that follows the shape, and two holes on the upright centre line for the post clips or a channel. Generic shapes only: lay out an official sign's face to its own regulations. The size is the circle's diameter, the triangle's, diamond's and square's side, or the octagon's size across its flats. The blank and its holes are cut (layer 0); the border is on layer 8 (print or apply it).
Sign making
Sign panel
Sign making: a flat sign panel - rectangular, with rounded or cut corners, oval, or with an arched top - and its fixing holes a set distance in from the edges: two (one each end), four (the corners), six (and the middle of the long sides) or eight (and the middle of every side); on an oval they sit evenly round an oval that far inside it. The holes are cut with the outline (layer 0); the stand-offs' caps, if you fix it on stand-offs, are drawn round them on layer 8 so you can see they clear the lettering and the edge. The stand-offs are accessories: shown in 3D and costed by the Accessories and fitments report, each cutting its own hole.
Sign making
Stencil plate
Sign making: a stencil plate: a plate with a ring, a square frame or a target (two rings) cut through it, held together by bridges: strips of the plate left across the cut so the middle (the island, as in an O) stays attached. The bridges are parallel-sided, the bridge width across, evenly round from the top (a pair: top and bottom). The cut-outs and the plate's outline are cut (layer 0); the centre lines are on layer 8.
Sign making
Tray sign blank
Sign making: a tray sign blank: a sign face with a return (a folded edge) bent back on all four sides, flat, so the sign stands off the wall and looks thick. Sizes are the finished face and the return's depth, outside. The flat blank allows for each bend (the bend allowance from the material's K-factor, thickness T and inside bend radius R: BA = π/2 × (R + K × T); the flat face the outside size less the set-back R + T at each bend). Where the bends meet, each corner is relieved so the returns fold without tearing: a round relief, a square one, or the plain corner notch. Bend lines are on layer 1; fixing holes in the returns are optional. Check the K-factors against your press brake.
Stone and tile
L-shaped worktop
Stone and tile: an L-shaped worktop in two pieces joined at the corner (a butt joint, or a mitre), with an undermount sink cut-out and tap hole in one leg and a hob cut-out in the other, each set back from the front edge and placed along the run; drainer grooves beside the sink if wanted. L is the long leg's length along the back wall and W the short leg's, D the worktop's depth (front to back). The cut-outs' corners are rounded as the stone needs. Cut on layer 0; the joint and the grooves (to route) on layer 8.
Stone and tile
Splashback and upstands
Stone and tile: a stone splashback behind a hob or a sink, with cut-outs for sockets set out along it, and the upstands that run along the rest of the wall, cut from the same slab; the upstands' joints fall at the splashback's ends. L is the run of wall, W the splashback's height and D the upstands' height; the splashback is SPW wide, its middle SPX along the wall. Cut on layer 0; the sockets' centres on layer 8.
Stone and tile
Vanity top
Stone and tile: a vanity top: a slab L wide and D deep with an undermount basin cut-out (an oval, a rectangle with rounded corners, or round) centred on its width (or two basins), a tap hole or a three-hole mixer behind each, and an upstand along the back and the sides if wanted. The cut-outs keep at least 50 from the edges. Cut on layer 0; the basins' centre lines on layer 8.
Stone and tile
Wall tile layout
Stone and tile: a wall's tile layout: the wall L wide and W high set out with tiles of a size, the joints between them, in stack bond or brick bond (each row moved along by half, a third or a quarter of a tile), set out from a joint (or a tile) in the middle of the wall so the cut tiles at either side are the same. Whole tiles are drawn on layer 8 and cut tiles on layer 0, and how many of each and the narrowest cut are printed (add a few for breakage).
Structural steel
Angle cleat pair
Structural steel: the marking-out layout for a pair of angle cleats (a double-angle web cleat connection): two cleats cut from an angle section, one each side of the supported beam's web, bolted through the web with one line of bolts and to the column or supporting beam with the other leg. Each cleat is drawn opened out flat, its two legs either side of the heel (layer 1), sizes measured from the heel (the angle's back), for marking the holes on the cut lengths. The bolt sets the holes (2 mm clearance, 3 mm over M24), the end distance (1.5 × the hole) and the pitch (3.5 × the bolt), rounded up to 5 mm; each leg's gauge (the hole line from the heel) is half the leg plus its thickness, rounded to 5 mm. The longer leg of an unequal angle goes on the column. Check the connection with the engineer.
Structural steel
Beam cope template
Structural steel: a template for marking a cope (notch) in the end of a beam that frames into another beam with their tops level: the top flange and some of the web cut away so it clears the supporting beam's flange. Cut the template out, lay it on the coped beam's web, its square end at the beam's end and its edges at the top and bottom of the beam, and mark round the notch. The supporting beam sets the cope: its depth clears that beam's flange and root radius by 5 mm, its length clears the flange's outstand by 10 mm (the coped beam's end standing 10 mm off the supporting web), both rounded up to 5 mm; the inside corner is rounded (drill it, then cut to it). Cope the bottom too when that beam's bottom flange is in the way. Check the coped section with the engineer.
Structural steel
Beam end plate
Structural steel: an end plate welded to a beam's end and bolted to the column or beam it frames into: flush with the beam (a little past its flanges), or extended past the top flange (or both flanges) with a row of bolts there. The beam sets the plate's depth and the beam's outline, drawn on the plate on layer 8 where it is welded. The bolt sets the holes (2 mm clearance, 3 mm over M24), the edge distance (1.5 × the hole), the pitch (3 × the bolt) and how far the rows sit from the flanges (1.5 × the bolt + 15, room for the weld and a spanner), all rounded up to 5 mm; the cross-centres clear the web and its welds the same way, and the plate is made wide enough for them. The rows inside the flanges are spaced evenly. Weld sizes and preparation are for the engineer.
Structural steel
Bracing gusset plate
Structural steel: a gusset plate for a diagonal brace, in the corner between a beam (along the bottom edge) and a column (along the left edge), welded to both; the brace is bolted to it along its centre line at the brace's angle, the centre line running through the corner (the work point). The bolt group starts far enough out that every bolt is clear of both edges by the clearance (3 × the bolt, for the brace's end and a spanner), and the plate runs E past the last bolt, square to the brace. The bolt sets the holes (2 mm clearance, 3 mm over M24), the edge distance (1.5 × the hole) and the pitch (3 × the bolt), all rounded up to 5 mm. The corner can be sniped to clear the beam's and column's welds. Check the design with the engineer.
Structural steel
Column base plate
Structural steel: a column base plate, holding-down bolts in the corners (and the middle of the long sides, if wanted), with a grout hole. The bolt sets the holes (2 mm clearance, 3 mm over M24) and the least distance from their centres to the plate's edges (1.5 × the hole); the plate's grade and thickness are printed for the cutting list. Check the design (the plate, the bolts, the weld) with the engineer.
Structural steel
Fin plate
Structural steel: a fin plate (shear tab): a plate welded along one edge to the supporting column or beam, and bolted through the supported beam's web, with one or two vertical lines of bolts. The welded edge is on the left. The bolt sets the holes (2 mm clearance, 3 mm over M24), the end and edge distances (2 × the bolt, rounded up to 5 mm) and the pitch (3.5 × the bolt, rounded up to 5 mm); the first line is a 10 mm gap (to the beam's end) plus the edge distance from the weld. The top corner on the welded edge can be sniped, to clear the root radius where a supporting beam's web meets its flange. Check the connection with the engineer.
Structural steel
Lifting lug
Structural steel: a lifting lug (padeye): a plate welded on its straight base, with a rounded head round the hole for a shackle's pin. The sides run straight from the base's corners to touch the head's circle (tangents). The pin sets the hole (2 mm clearance, 3 mm over 25 mm) and the head's radius (1.5 × the hole, rounded up to 5 mm, leaving as much steel round the hole as the hole is across). Choose the shackle to suit the pin and the lug's thickness to suit the shackle's jaw. A lug's capacity, its weld and the load's direction must be checked by the engineer; mark the lug with its safe working load once it is.
Structural steel
Splice plate
Structural steel: a splice plate (cover plate) joining two members end to end: a flange splice (a few bolts along, two lines across) or a web splice (two or three along, several lines up the web). Each side of the joint has the same bolt group: bolts along the plate at the pitch, lines across it at an even gauge. The bolt sets the holes (2 mm clearance, 3 mm over M24), the edge and end distances (1.5 × the hole, rounded up to 5 mm) and the pitch (3 × the bolt, rounded up to 5 mm); the members' ends are a gap apart at the plate's middle. The plate is made wide enough for its lines of bolts. Check the design (the plate, the bolts, the slip) with the engineer.
Structural steel
Web stiffener
Structural steel: a web stiffener for an I-beam or column: a plate fitted between the flanges against the web, one each side (cut 2 for each position). Its inner corners are sniped at 45° to clear the root radii where the web meets the flanges. The beam sets its height (between the flanges) and width (the flange's outstand, set back 5 mm from the flange's edge) and the snipe (the root radius plus 5 mm, rounded up to 5 mm). Fitted to both flanges, or cut short of the bottom (tension) flange by 4 × the web's thickness. Check it with the engineer.
Vinyl cutting
Circle and rectangle decals
Vinyl cutting: printed decals for print-and-cut: a sheet of round, rectangular, rounded or oval decals in rows and columns, the print area of each on the Print layer, and the contour cut round it a bleed out on the Contour Cut layer (the print runs on past the cut by the bleed, so no white edge shows). Registration marks for the cutter's optical eye (squares, printed) at three corners of the sheet, a margin out, on the Registration layer.
Vinyl cutting
Lettering plate
Vinyl cutting: a lettering plate: the panel a line of vinyl lettering goes on, sized from the letters' height (the capitals') and how many there are, with the margins a sign maker leaves (half a letter's height all round). The plate is cut (layer 0); the baseline, the capital height and the lettering itself, centred, are guides on layer 8; a weed border round the lettering is on the Weed layer. Cut the lettering with the Weed Border and Weed Lines tools once the letters are drawn over the guide.
Vinyl cutting
Numbering plates
Vinyl cutting: numbering plates (house numbers, race numbers, locker or table numbers): a run of plates numbered in order from the first number, in rows, each cut (layer 0) as a rectangle, a rounded rectangle or an oval, with its number centred on it as a guide for the vinyl or the print (layer 8).
Vinyl cutting
Stripes and pinstripes
Vinyl cutting: a set of stripes for a vehicle or a wall: a wide stripe with pinstripes beside it, or a pair of racing stripes, each a cut outline (layer 0), a gap apart, along a length; their ends square, pointed or cut at 45°. The stripes are laid one above another as they go on.
Vinyl cutting
Vehicle door panel
Vinyl cutting: a vehicle door panel template: the door's flat panel (its size for the vehicle chosen, or your own), its corners rounded, cut (layer 0); inside it, on layer 8, the safe area for lettering (in from the edges and the swage line), the door handle's recess and the lock, which graphics should keep clear of, and a centre line. Measure the door and change the sizes to suit: a panel wider than the roll can be split with the Tiling tool.
Vinyl cutting
Weeding box template
Vinyl cutting: a weeding box template: the area a piece of lettering or a logo takes (a guide on layer 8), a weed border round it a margin out (cut, on the Weed layer) - a box, or a box with rounded corners - and, if chosen, weed lines up the margin every so far, so the waste peels off in strips (WEEDLINES on the guide: they stop at it). Put the design inside the guide: the Weed Border and Weed Lines tools then fit the border and the lines to the design.
General
Tray
A parametric drawing for File › Run Parametric: a tray blank, its base L × W, walls D high, glue flaps on the corners. Its labelled variables are asked for before it is run, each with a control of its kind: a number, a choice (a list or dictionary indexed by a fixed key), yes or no (TRUE or FALSE), or text. Copy it to your Extensions folder (File › Extensions › Open Extensions Folder) and make your own.
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