@James Walters
Hi James,
I'm not convinced there is a problem, but without a laser-cutter I can't be sure. If I had a machine, my intended way of working would likely be:
1. make a trial cut in the desired material at the intended power settings.
2. measure the kerf using feeler gauges.
3. set that as the kerf setting in Templot.
4. export a file to make a test piece and measure it (cutting the sockets
before the timber outline).
5. adjust the DXF socket size and scaling settings as necessary.
We seem to be going round in circles. Here's some stuff I posted 18 months ago:
This is how it is intended to look immediately below the chair base:
The plug dimensions (pink+red) are taken directly from the prototype at 1" inside the chair base all round, so for an S1 chair the plug is 6" x 12.5" (2.0mm x 4.17mm in 4mm/ft scale).
The socket dimensions (green) are then set so that there is an easy fit or small clearance at the sides of the plug, and an interference overlap (red) at each end of the plug to create a bash press-fit. In the FDM bases this causes the plastic to be deformed sideways into the green clearance spaces, creating a firm interference fit and an accurate track gauge. In the CNC milled bases, the MDF material compresses to produce the same result. The idea of a bash fit is that it is more tolerant of variations in socket size (caused by the fixed printer resolution) than a traditional engineering press-fit.
I'm not too sure how this would work best in plywood bases, and without my own precision laser-cutter to conduct experiments it is difficult to find out. I imagine the red overlap might need to be increased to achieve a firm fit, by reducing the socket length. Alternatively you might need to abandon the idea of a press-fit and glue the chairs in place.
I don't think anything much has changed with regard to laser-cutting.
For FDM I have since introduced the easy assembly clip-fit option, which allows for a greater socket clearance to accommodate the variations and rounding effects in different FDM printers, while still retaining the chair firmly in the timber. But it still requires a close fit at the socket ends to ensure an accurate track gauge.
All the default socket size settings:
View attachment 8465
View attachment 8464
have been derived from trials with FDM printers, so I would expect them to need changes for laser-cutting (and CNC milling).
I think perhaps I should post a bit more about FDM printing, to restore the balance of discussions here on Templot Club. I'm sure there are more users interested in that than in using smoke and mirrors.
cheers,
Martin.