The cut sheets
1 sheet. 1220 × 2440 mm, 18 mm plywood. Total cut path 50.1 m.
Machine time for the whole unit: about 1.7 h best, 3.2 h typical, 7.5 h slow. Based on reported 120 W-class diode speeds, multiple passes at 18 mm. One timed scrap cut will replace this.
A commercial CO2 flatbed is about 1.5 h in the sourced case. That number is an assumption, not a cut on this machine.
Sheet 1 carries a fit-test coupon: cut it first and try the tab in the slot before you cut the rest. Hover or tap a part below to light it in the model.
Build stages
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1
Cut the sheet about 334 min (5 h 34 min)
Cut the fit-test coupon first (slot = tab + 0.1 mm), then the 29-part sheet from the DXF (CUT layer): 50 m of path. The cart is the densest nest: expect a long run, so check the sheet is flat and weighted before starting.
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2
Remove char and sand about 60 min (1 h)
Brush the char off every edge, sand 120 then 180 grit, ease the worktop edge and the shelf fronts by hand.
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3
Dry fit about 20 min
Stand SIDE-L and SIDE-R on BASE, add BACK, RAILs, the worktop, and slide in a SHELF on its LEDGERs. Check the shelf-slot pitch (50 mm) and that the tabs end flush.
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4
Pre-finish about 60 min (1 h)
Seal every face now, the worktop most of all (kitchen use: water-based poly, 3 coats on top). Mask the tabs and slots so the glue bonds to bare wood.
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5
Feet and casters about 30 min
Glue and screw the FOOT-A and FOOT-B pairs under the base (8 x #8 x 1-3/4 in), then bolt the 4 casters on the 73.2 x 44.5 mm pattern with M8 bolts and nuts. Fit at least 2 locking casters.
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6
Glue-up (Titebond III) about 35 min
Glue SIDE-L and SIDE-R onto BASE, the BACK, then the three RAILs, then set the worktop over the side tabs. Clamp across the width and check diagonals.
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7
Screws as clamps about 30 min
45 #8 screws in all: #8 x 1-1/2 in through the side faces and top; #8 x 1-1/4 in for rails and shelf locks. Pilots are laser-cut at 3.0 mm.
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8
Shelves and ledgers about 20 min
Screw a LEDGER pair into the slot row you choose, then drop in the SHELF and lock it with the 2 SHELF-LOCK screws. Move rows in 50 mm steps for tall appliances.
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9
Optional drawer and cleat about 45 min
Drawer: glue the finger-jointed box, drop in the bottom, screw DRW-FACE, set on its DRAW ledgers. Cleat: glue the two CLEAT-BACKER layers to the back and fit the Z-bar. A loaded cart is not wall-hung: use the cleat for an empty/tidy-storage version only.
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10
Finish, load test, pack about 40 min
Final coat, 24 h cure, a 40 kg load test rolled across a doorstep, lock check on a slope, then flat-pack.
About 11 h 14 min for all 10 stages.
Materials and hardware
18 mm (3/4 in) sanded plywood (basic birch-faced or cabinet ply), 4 x 8 ft x 1. Thickness 18 mm. 1 sheet.
Glue: Titebond III, about 4 oz.
Finish: water-based poly, 3 coats on the worktop (about $14).
| Hardware | Qty | Each | Line |
|---|---|---|---|
| #8 x 1-1/2 in wood screws from model | 20 | $0.06 | $1.20 |
| #8 x 1-1/4 in wood screws rails, shelf locks, drawer face | 13 | $0.06 | $0.78 |
| #8 x 1-3/4 in wood screws feet, cleat backer | 12 | $0.08 | $0.96 |
| 3 in locking swivel casters (73.2 x 44.5 mm plate, M8) ASSUMPTION: about $7 each, 2 locking minimum | 4 | $7.00 | $28.00 |
| M8 bolt + nyloc nut sets caster mount | 16 | $0.35 | $5.60 |
| Aluminum Z-bar French cleat pair optional, empty / light-duty wall version | 1 | $8.00 | $8.00 |
| Felt/rubber stops drawer | 2 | $0.50 | $1.00 |
| Hardware total | $45.54 |
Screws counted from the model: #8 x 1-1/2 in × 20, #8 x 1-1/4 in × 13, #8 x 1-3/4 in × 12.
Profit estimate
Estimates and assumptions. Every dollar figure on this page is a planning estimate, not a quote and not a promise. Sheet price, hardware, fees, labor, and machine wear are assumptions. Machine time is based on reported 120 W-class diode speeds, multiple passes at 18 mm. One timed scrap cut will replace this.
Diode machine time
These three columns are the same unit at the mid selling price. Best, typical, and slow are the diode estimates. Based on reported 120 W-class diode speeds, multiple passes at 18 mm. One timed scrap cut will replace this.
| Best | Typical | Slow | |
|---|---|---|---|
| Machine time | 1.74 h | 3.23 h | 7.45 h |
| Cost per unit | $139.50 | $142.03 | $149.20 |
| Gross margin | $140.50 | $137.97 | $130.80 |
| Gross margin % | 50.2% | 49.3% | 46.7% |
| Net after fees and labor | $37.50 | $34.97 | $27.80 |
| Gross profit per machine hour | $80.75 | $42.71 | $17.56 |
| Net profit per machine hour | $21.55 | $10.83 | $3.73 |
Commercial laser (assumptions)
These columns are assumptions, not a cut on this machine. ASSUMPTION. Sourced case: 300-600 W CO2 flatbed, single pass at ~600 mm/min (vendor 480-720), 60 m/min rapids, 5 min/sheet, $8/h operating cost. What-if cases: a machine 10x / 20x faster than the diode mid cut+travel time (not sourced for 18 mm ply).
| Commercial CO2 (assumption) | What-if 10× (assumption) | What-if 20× (assumption) | |
|---|---|---|---|
| Machine time | 1.49 h | 0.38 h | 0.23 h |
| Cost per unit | $148.46 | $139.58 | $138.38 |
| Gross margin | $131.54 | $140.42 | $141.62 |
| Gross margin % | 47.0% | 50.2% | 50.6% |
| Net after fees and labor | $28.54 | $37.42 | $38.62 |
| Gross profit per machine hour | $88.28 | $369.53 | $615.74 |
| Net profit per machine hour | $19.15 | $98.47 | $167.91 |
Selling price, at the typical diode time
| Low price | Mid price | High price | |
|---|---|---|---|
| Selling price | $180.00 | $280.00 | $420.00 |
| Cost per unit | $142.03 | $142.03 | $142.03 |
| Gross margin | $37.97 | $137.97 | $277.97 |
| Gross margin % | 21.1% | 49.3% | 66.2% |
| Net after fees and labor | -$55.03 | $34.97 | $160.97 |
| Machine hours | 3.23 h | 3.23 h | 3.23 h |
| Gross profit per machine hour | $11.76 | $42.72 | $86.06 |
| Net profit per machine hour | -$17.04 | $10.83 | $49.84 |
ESTIMATE: 3.2 h (low-speed case 7.5 h, best case 1.7 h) of machine time per unit for 50 m of cut path in 1 sheet(s) on a 120 W diode, 18 mm plywood. Machine time, not material, is still the limit on profit per hour, but a single test cut on scrap will replace this range with a real number.
All dollar figures are planning ESTIMATES / ASSUMPTIONS, not quotes, not guaranteed. Sheet prices: 4x8 ft 18 mm birch plywood $70-110, basic plywood $55-75 (assumption). Machine time uses a sourced RANGE for a 120 W diode on 18 mm ply (low 120 / typical 300 / high 600 mm/min effective, i.e. after multiple passes; taken from reported speeds for a 120 W-class diode); ACMER publishes no 18 mm ply feed rate, so none of it is measured on this machine. Machine wear/electricity $1.70 per machine-hour (assumption). Labor valued at $25/h for the "after labor" line only. Marketplace fees 10% (assumption, e.g. Etsy-style).
Where the price band came from: Assumption: $180-$420 band, set against 2-shelf rolling kitchen carts at roughly $70-$250 retail [third-party estimate]
Try your own numbers
Change the sheet cost, hardware, selling price, labor rate, or machine time. Finish ($14.00) and packaging ($12.00) stay put. Machine wear follows the machine-time choice: $1.70 per hour on the diode estimates, $8.00 per hour on the commercial assumptions. Fees stay at 10% of the selling price. Labor uses the planned 3 h at the rate you type.
Still an estimate. Based on reported 120 W-class diode speeds, multiple passes at 18 mm. One timed scrap cut will replace this. The commercial rows are assumptions, not a cut on this machine.
Parameters
These are the knobs for a custom order. The model on this page uses the defaults. Stay inside the limits.
| Parameter | Default | Limits |
|---|---|---|
| Width | 600 | 450-750 mm (over 750 would need a centre post; not modeled) |
| Depth | 450 | 380-560 mm |
| Height | 900 | 760-1000 mm |
| Thickness | 18 | 17.5-19 mm |
| Slot clearance | 0.1 | 0.0-0.2 mm |
Safety notes
- Locking casters: lock at least two on any loaded or worktop use.
- Cart load rating is untested: target 40 kg shelves + 20 kg worktop, UNVERIFIED. Load test every design change.
- Tip: the cart is 900 mm tall and narrow; keep heavy appliances on the lowest shelves and do not roll over thresholds loaded.
- Do not run heat-producing appliances on the ply unprotected: use a trivet.
- Not a children's product (no CPSIA testing).
Unverified / to test
- Machine time is an estimate (120 W diode on 18 mm ply, sourced range, not measured on this machine); cut time and profit/hour depend on it.
- Load and tip behaviour untested.
- Price band is my assumption (cart was not part of that price survey).
- Caster price and fit are from the original design; the hole pattern is assumed for common 3 in plate casters.
- Depth and width ranges were build-checked only at the stress variants (400-520 mm deep, 480-800 mm wide).
Downloads
Meadowlark Models. Numbers on this page are estimates. Machine time is based on reported 120 W-class diode speeds. One timed scrap cut will replace it.