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Chapter 8

Making Sketches and Mockups

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Sketches and mock-ups are useful aids when designing, laying out, and producing cabinetry. The old saying that a picture is worth a thousand words is very appropriate to sketching. A quickly made sketch conveys information that would be difficult to describe otherwise. A sketch records your ideas and makes communications easier.

Sketching is part of the design process. Sketches are made to record ideas for a product. Later, they are relied upon for preparing working drawings. During production, sketches are also made. They may show changes in the original design. Some might refer to machine or equipment setups.

Mock-ups are three-dimensional replicas of your design made of convenient inexpensive materials. They could be paper, cardboard, or scrap wood. They are used for analysis of your design before the product is built. The mock-up may be a full scale replica or a scaled-down version of the product.

Summary

The value of sketches and mock-ups is to present a design solution. Sketches and mock-ups can save time in communications. They allow you to record and communicate ideas quickly and clearly.

A sketch might illustrate a product to be built. It could describe a jig or fixture for production. A mock-up may represent the basic shape of a product. It might illustrate how a product looks or how it works. Any or all these practices can prevent wasted time and materials.

Sketches generally illustrate three views of an object. Most people visualize an object in this manner. Isometric and cabinet sketches are quite common. Perspectives are not used as much, because they take longer to prepare. Sketching is simple to master. You must first learn to create simple lines and circles. Practice will make you proficient at sketching these and more complex geometric forms.

Mock-up building is more involved. You must measure, cut, and assemble components made of inexpensive material. Appearance mock-ups look like the final product, but are not functional. Hard mock-ups may not be finished like the final product, but they are scaled, functional models used to analyze how the product will work.

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Chapter 9

Producing Working Drawings

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Creating an original design challenges even the most experienced cabinetmaker. Begin by making decisions about the features you wish in the product. Then decide the best way to produce the product. Next, make sketches that show this information. From these sketches prepare the working drawings. Working drawings contain the graphics, measurements, and notes needed to build the product.

Working drawings for cabinets, case goods, chairs, and tables is part of drafting technology. Activities include laying out geometric forms, ­transferring designs, and providing details. The equipment and supplies to construct the working drawings varies. You might be using a computer and computer software or you may be drawing by hand.

Summary

Cabinetmakers who design as well as build products have to prepare working drawings. Computers and computer software are being utilized for cabinet design applications. In addition to design, computers are being used for performing automated drafting, reproducing and updating designs, parts lists and bill-of-material information, material optimization, estimating and job costing, part and product labeling, part machining, machinery linking, and appliance guide.

Use the appropriate supplies to produce accurate work. Equipment includes a straightedge, drawing board, triangle, lead holder, paper, compass, scale, and templates.

Working drawings contain information essential in describing the product. Title blocks identify the product, scale, drafter, and other details. Multiview drawings show the layout of all parts of the design. Dimensions give measurements of each part. Detail drawings further explain intricate features of the design. 

The bill of materials lists the materials needed to produce the product. This table includes part name or number, quantity, dimensions, manufacturer, and other important characteristics of the material. Many commonly used items may be stocked in quantity in the shop. Other components may be purchased.

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Chapter 10

Wood Characteristics

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Cabinetmakers who produce high-quality cabinetry understand wood characteristics. They are very careful about selecting, storing,  handling,  and processing wood to retain its desirable qualities. These qualities include natural beauty, strength, durability, elasticity, and easy maintenance.

Because of its varying color and pattern, wood has natural beauty. Cabinetmakers enhance this beauty through the shaping and finishing of wood products.

The structural qualities of wood make it a desirable building product. Pound for pound, some wood species are as strong as steel. Most will last for centuries with regular maintenance. If a wood product is marred, it can be resurfaced and refinished to restore the original beauty.

Wood is an elastic material. It will bounce back to its original shape after being dented or bent. This property is applied in the construction industry where wood beams are used as floor joists.

Summary

Wood has a natural beauty that makes it desirable for cabinetmaking and interior design. Wood also has structural qualities that meet the needs of construction.

Wood from deciduous trees is hardwood. Wood from conifer trees is softwood. This does not refer to the actual density or weight of the wood.

Growth in a tree occurs in the cambium. The cambium produces both bark cells and cells that carry nutrients to the tree. Growth in springtime is earlywood; growth in summer is latewood. Each growing season produces an annual ring.

The physical properties of wood include color, grain pattern, and surface defects. Most of these qualities are not seen until the tree has been cut into lumber.

The moisture content of wood has a significant effect on it. When the moisture content goes below fiber saturation point the wood begins to shrink. Shrinkage in lumber varies according to the section of the tree and how it was cut. The critical time to ­maintain an even moisture content is during processing.

Working qualities include dulling effect, reaction wood, and the density. The density of a wood describes weight per unit of volume. The more dense a wood is, the heavier and stronger it will be. Woods laden with minerals (dense woods), tension woods, and compression woods are harder to work.

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Chapter 11

Lumber and Millwork

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Wood is a worldwide resource for cabinetmaking and construction materials. Wood is a source for lumber, millwork, and manufactured wood products. Lumber is purchased in nominal size boards (1 x 3, 2 x 4, etc.) for softwood construction or random widths and lengths (RWL), which is for hardwoods used for cabinetmaking. Millwork includes manufactured dowels, moldings, and decorative wood pieces. Manufactured wood products include plywood, particleboard, and fiberboard.

All wood species are brought to market as lumber through a sequence of steps. These include harvesting, sawing, drying, and grading. Individuals or industries then order lumber and millwork to meet their needs.

Summary

Lumber begins its journey to you as a mature tree being harvested. Logging industries select and fell trees for market by sectional felling and systematic felling. Sectional felling is when large sections of a forest are cut at one time with heavy machinery. Clearing large portions of a forest is less expensive than cutting individual trees. Systematic felling is when trees are singled out for harvesting. They may be selected because wood of that specie is needed.

At the lumber mill, logs are loaded onto a jack ladder and transported to a preparation area. There, they are washed and sometimes debarked in preparation for sawing. Lumber is sawed by the three methods of plain sawing, quarter sawing, and rift sawing. Because of increased handling time, quarter-sawn and rift-sawn lumber are more costly than plain sawn lumber. After sawing, lumber must be dried by air drying or by kiln drying to reduce the moisture content. The drying process is called seasoning.

Lumber defects detract from the appearance and workability of the wood. Cabinetmakers need to know how defects affect both the aesthetic and structural properties of the wood. The three categories of defects are natural defects, defects caused by improper seasoning or storage, and defects caused by machining.

After seasoning, lumber is graded according to quality. Lumber grading is a matter of judgment and experience. Graders rate each piece according to the size of board and amount of defect free lumber in it. The clear cuttings, or yield, of a board needed to achieve a certain grade will differ between hardwood and softwood. It also can differ between species.

Ordering hardwood and softwood lumber involves specifications. A cabinetmaker must deal with qualities, quantities, conditions, and species when ordering materials.

Millwork consists of specialty items frequently processed from molding grade lumber. Example items are molding, trim, and specialty items, such as legs, spindles, finials, dowels, plugs, buttons, and carvings. Only a few wood species are processed into millwork items. These species have excellent machining properties and are less likely to warp.

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Chapter 12

Cabinet and Furniture Woods

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Wood is the most versatile material used by humans when shaping their living environment. In an age of synthetic and metal surroundings, wood still serves many needs. It forms the shape of our houses and decorates our interiors. It provides structure for case goods that store our belongings.

Besides being a structural material, wood conveys an aesthetic beauty which few materials can match. Today, as in centuries past, hardwood furnishings are preferred by those who want the finest that nature can offer. Although wood grain plastics may cover much of today’s furniture, they cannot fully imitate solid wood.

Various species of wood grow in all parts of the world. Each has different properties, including color, density, flexibility, etc. Woods of the same species even may differ in color and hardness. Identifying wood species requires careful analysis. You must look at grain pattern, pores, color, odor, weight, and hardness. Wood for furniture should be less likely to warp or shrink and have a pleasing appearance.

Summary

Wood is the primary material in shaping our living environment. It is used for tables, chairs, walls, and entire structures. Wood has so many uses because it is both functional and attractive. Functional qualities include hardness, flexibility, and shock resistance. Aesthetic qualities include color, texture, and grain pattern. The chart in Figure 12-45 summarizes the characteristics of each wood species. Your selection of a wood will be based on those qualities that you feel are most important.  (Note: Figures and photo images are not included in the on-line summaries. Charles W. Davis)

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Chapter 13

Manufactured Panel Products

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Manufactured panel products are widely used by cabinetmakers to create large surfaces for case goods. They reduce the need for edge gluing lumber to make wide boards. Production time is reduced without sacrificing quality.

Panel products are typically more stable than solid lumber. They warp less because they are constructed with layers of thin wood or wood fibers. There is no continuous grain pattern in a panel. This keeps distortion at a minimum. Some panels are even moisture resistant.

The faces may be rough, textured, smooth, or finished. The appearance of higher grades is suitable for clear finish. Lower grades contain defects. Veneered panels look like solid wood lumber. Those made of wood chips or fibers do not resemble real wood. Selection is based on whether the panel is to be hidden or visible.

The edges of veneered and nonveneered panel products reveal their composition. Edges are either hidden in the joint or covered with wood tape, plastic strips, or edging.

There are three categories of panel products. These products are structural wood panels, appearance panels, and engineered board products.

Summary

Manufactured panel products are widely applied in case goods and fine furniture. Most consumers seldom know whether the product they are buying is solid lumber or a veneered or laminated panel product. For the most part, it doesn’t matter. Most manufactured panels are stronger than solid lumber.

The three types of manufactured panel products are structural wood panels, appearance panels, and engineered board products. Most structural wood panels are used in building construction. These are performance-rated panels. Others are used in cabinetmaking. Veneered panels, such as plywood and composite board, can be used in assembling case goods.

Most interior woodwork is made with appearance panels. Hardwood plywood is a common material for modern cabinets and fine furniture. It has the appearance, strength, and durability of solid lumber, yet is much less expensive. Other appearance panels, such as prefinished plywood, simulated wood grain, and prehung wallpaper paneling, make good wall covering.

Engineered board products are fabricated for special purposes. Hardboard and mende particleboard are used as drawer bottoms, cabinet backs, and other applications requiring thin panels. Medium-density fiberboard is often used as a substitute for lumber moldings, drawer fronts, and various millwork.

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Chapter 14

Veneers and Plastic Overlays

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Veneers and plastic overlays are used in most cabinetry and fine furniture manufactured today. An overlay is any thin, sheet material that typically covers a core material, such as plywood, MDF, or particleboard. The core material is known as the substrate.

When the product has a wood veneer, simulated wood melamine or vinyl laminated on its surface, it looks as if it were constructed with solid lumber. Decorative designs such as natural stone and solid colors provide other attractive appearances.

Plastic overlays have an advantage over wood veneer. Plastics provide a nearly indestructible covering that requires no additional finish. Plastic overlays are fabricated from layers of synthetic materials. They may be rigid or flexible. Wood grain, solid colors, simulated stone, or other decorative designs may be printed in them.

Veneer and plastic overlays are frequently used to create decorative surfaces and edges. The art of veneering (inlaying and overlaying) has existed for centuries. Veneer murals unearthed in Egypt date back to 1500 BC. During the Dark Ages, veneering was abandoned, but in the 17^th and 18^th century a revival of veneering was seen in European traditional furniture. Today, most veneer is used as overlay for cabinet surfaces. The art of veneering is not so common in modern design. Straight line and plain designs are the preferred styles.

Veneer is cut from many wood species. Most softwood veneer is used to make structural plywood for building construction. Hardwood veneer is used for cabinetmaking and architectural purposes. Wood cabinets are seldom made from either lumber or plywood. Thermally fused melamine particleboard panels are the primary materials. Hardwood veneer on a substrate combining particleboard and softwood veneer is also replacing plywood. Hardwood veneer is also laminated to thin plywood or fiberboard to be installed as paneling.

Summary

Veneers and overlays dominate the cabinetmaking industry for product surfaces. They cover wood product panels, such as particleboard. They create finished, mar-resistant surfaces to countertops, table-tops, and case goods. Veneers and overlays provide a durable, low-cost alternative to solid lumber.

The veneer cutting method determines the grain pattern. The rotary cutting method is used nearly 90% of the time. It produces the most square footage of veneer from a log. Other cutting methods may have exclusive applications for a certain wood specie. Once the veneer is cut, it is clipped and dried.

Veneer is often matched to produce pleasing effects. Commonly assembled matches include book, slip, and diamond.

Plastic overlays are almost indestructible. High-pressure decorative laminates are rigid overlays manufactured using layers of resin soaked paper bonded under heat and high pressure. Thermally fused melamine is manufactured by bonding resin soaked paper to the substrate under heat and pressure. Flexible overlays are made from vinyl. Both rigid and flexible overlays provide durable, stain-resistant surfaces. Wood veneer and plastic ­overlays are also used for edgebandings and trim. Veneer bands are often inlaid into routed grooves in solid wood.

Using veneers and overlays will greatly reduce the cost of your product. When installed carefully, they will provide years of durable service.

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