led + cnc fractal headboard

8/11/2019 LED + CNC Fractal Headboard

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dmvaldman

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Shop Bot Headboard

by SchweezyRider

LED + CNC Fractal Headboard by dmvaldmanDownload

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Here's how to make a headboard based on the Pythagorean tree fractal and

backlight it with LEDs. This instructable can be modded to make similar CNC

lightbox silhouette effects. If you don't have access to a CNC machine, you can

also do something similar - albeit smaller scale - on a laser cutter.

My bed frame has a 57" space that my pillow would always recede into. There

was only one thing to do...

AutoCabinetsSoftwareroutercad.com

CAD/CAM Software for CabinetmakersNested Based Mfg. CNC Millwork

tesa 4965

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Step 1: Materials

Main Materials:

4'x8' sheet of plywood - I used 1/2" thick birch from MacbeathLED light strip (at least 15 ft) - I used these from Amazon

Remote ControlPower Adapter

Diffusive paper - I used a roll of Vellum from Amazon

Odds & Ends:

Wood glueWood pre-stain, stain, finish (polyurethane)Sandpaper1/4" x 2" Bolts and 1/4" Nuts (14)

Tools Used:

Shopbot CNC router (or laser cutter if smaller project)Belt Sander (optional)Drill (optional)

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by trev25
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3/10

Glue gun (optional)

It's important to get high-quality plywood. Cheap plywood will have many gaps,

which will be exposed after CNCing.

I did most of the work at TechShop SF.

Step 2: Getting the files

[optional background] To create the design, I used Paper.js, a JavaScript

library for generating SVG in an HTML canvas element. I scripted Paper.js to

make the tree fractal. If you're curious about generating fractals on the web,

you can find the files below, just unzip and open index.html in your favorite

browser.

I've included to Adobe Illustrator file that I used to create the headboard below.

The dimensions of the Illustrator file are exactly 98" x 48", the size of a sheet of

plywood. I used a software called VCarve Proto turn this Illustrator file into G-

code for the Shopbot.

The plywood is cut into two main pieces, making the FRONT and BACK of the

headboard. Instead of using joints to give the headboard depth, I opted to CNC

a "frame". That's what all those thin slabs are in the Illustrator file. They've

been marked with numbers that match the edge of the FRONT piece (note: the

bottom edge is cut into two slabs for support: 5 and 6). For each edge, there

are two identical slabs, each a half inch thick, which stack on top of one

another. This makes the depth of the headboard = 4 * .5" = 2" (FRONT, BACK,and two layers of slabs).

1/4" holes are drilled through the edge slabs and the FRONT and BACK. Bolts

are placed through the holes to line everything up and support the structure.

This ended up being better than making joints, which would cause small gaps

when CNCed and expose the endgrain.

There is a small difference in the frame where 4 and 5 meet from where 7 and

6 meet. At (4,5) the frame creates a perfect seal, while at (7,6) the frame has

an opening to give power to the LED strip.
http://www.techshop.ws/http://paperjs.org/http://www.vectric.com/products/vcarve-pro.htmhttp://www.vectric.com/products/vcarve-pro.htmhttp://cdn.instructables.com/FBD/Y6FZ/I04653JP/FBDY6FZI04653JP.LARGE.jpghttp://cdn.instructables.com/FBD/Y6FZ/I04653JP/FBDY6FZI04653JP.LARGE.jpghttp://www.vectric.com/products/vcarve-pro.htmhttp://paperjs.org/http://www.techshop.ws/


4/10

pytree_html_files.zip 86 KB

headboard_fullSize_final.ai 902 KB

Step 3: CNCing

I used a 1/8" endmill bit for the detail on the fractals, and a 1/4" endmill bit for

the outer profiles and drilling. Then I sat back and waited for 4 hours while I

machine did all the work.
http://www.instructables.com/files/orig/FGI/OCJN/I0464Y7U/FGIOCJNI0464Y7U.ziphttp://www.instructables.com/files/orig/F3C/V1R0/I0464ZFL/F3CV1R0I0464ZFL.aihttp://cdn.instructables.com/FNV/2APE/I046495E/FNV2APEI046495E.LARGE.jpghttp://cdn.instructables.com/FNV/2APE/I046495E/FNV2APEI046495E.LARGE.jpghttp://www.instructables.com/files/orig/F3C/V1R0/I0464ZFL/F3CV1R0I0464ZFL.aihttp://www.instructables.com/files/orig/F3C/V1R0/I0464ZFL/F3CV1R0I0464ZFL.aihttp://www.instructables.com/files/orig/FGI/OCJN/I0464Y7U/FGIOCJNI0464Y7U.ziphttp://www.instructables.com/files/orig/FGI/OCJN/I0464Y7U/FGIOCJNI0464Y7U.zip


5/10

I was inconsistent with the tabs. I found all but the smallest cutouts should

have 1-2 tabs, because if a piece falls during drilling, you'll have problems as

the bit may try to laterally drill through them. The more tabs though, the more

sanding and filing you'll need to do after to get rid of them, which is very time

consuming and prone to error. Please leave a comment if you know a good

solution around this!

Step 4: Make the Frame
http://cdn.instructables.com/FQI/1VF1/I0465XFV/FQI1VF1I0465XFV.LARGE.jpghttp://cdn.instructables.com/FVM/419Z/I04655B2/FVM419ZI04655B2.LARGE.jpghttp://cdn.instructables.com/FWG/B5VG/I04649F2/FWGB5VGI04649F2.LARGE.jpghttp://cdn.instructables.com/FCJ/TG8J/I04649EQ/FCJTG8JI04649EQ.LARGE.jpghttp://cdn.instructables.com/FWB/NGO6/I04649AC/FWBNGO6I04649AC.LARGE.jpg


6/10

The slabs fit together to create a frame. I glued them to the BACK panel with

wood glue, keeping the panels bolted down while the glue dried. Don't forget towipe away those glue beads so you don't need to do as much sanding later.

After the wood glue dried, I glued the LED strip around the inner periphery of

the frame with a glue gun and cut the LED strip to fit.

I also used a drill with 1/2" Forstner bit on the backside of the BACK panel

around the drilled holes to keep the nuts flush with the back of the panel

(picture has wood already stained, sorry).

Step 5: Sand & Stain

Show All 7 Items
http://cdn.instructables.com/FI8/1221/I04649JR/FI81221I04649JR.LARGE.jpg


7/10

I suck at this part, so comments appreciated. Staining was hard because I

didn't want to get any stain on the endgrain of the fractal part. Using a brush

it's very easy for it to drip down onto the endgrain, so I used a cloth to rub the

stain on, which gave me more control, but ended up being blotchy (even with

pre-stain). Comments would be helpful if you have a good idea here.

Lots of sanding (especially all along the endgrain, a belt sander helped for this)

1 coat Minwax prestain

3 coats of Minwax Dark Walnut

3 coats of polyurethane spray.

Step 6: Add diffusive paper

I cut out a single sheet of vellum to fit the profile of the FRONT. I attached it

with masking tape. Rocket science.

I haven't played around much with other papers, like wax paper, parchment

paper, etc. Let me know if you think I should try something else in the

comments!
http://cdn.instructables.com/FGZ/2XGH/I04655QX/FGZ2XGHI04655QX.LARGE.jpg


8/10

Step 7: Done!

I can read without leaning to the side of the table lamp awkwardly now. The

light intensity can also be made very low for a calming effect. You can also get

a sound-reactive module for the LED strip, though I found it to be insensitive.

Currently, I'm making metal brackets to wrap around the bed frame and

support the headboard so it doesn't fall on me. I'll update this instructable whenthey're done!
http://cdn.instructables.com/FU1/VHDY/I0464A1W/FU1VHDYI0464A1W.LARGE.jpg


9/10

3 hours ago Reply

yesterday Reply

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rgoodrich

johnstat000

watchmeflyy

Uncle Kudzu

Tater Zoid

tomatoskins

dmvaldman(author) tomatoskins

Oh...I only need a Shopbot CNC router? lol

I suppose a really careful jigsaw job could do the trick...

Fractals are amazing! Super Cool.

Looks amazing!

Wow! It turned out really well. What a cool project! Reminds me of Gothicwindows.

Enhance where the magic happens, I love it.

Well that just turned out beautifully! Things that light up are always superfun!

thanks!

Make Comment
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10/10

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