Retail / Market Display Shelving

The cut sheets

Sheet 1 of 2

8 parts on this sheet. They cover 71.9% of a 1220 × 2440 mm sheet. Cut path 28.81 m. About 1 h 56 min at the typical diode estimate (best 1 h 5 min, slow 4 h 21 min).

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• 1 SIDE-L 440 × 1,500 mm Qty 1 Carcass
• 1 SIDE-R 440 × 1,500 mm Qty 1 Carcass
• 2 SHELF-1 864 × 440 mm Qty 1 Shelf
• 3 SHELF-2 864 × 360 mm Qty 1 Shelf
• 4 SHELF-3 864 × 280 mm Qty 1 Shelf
• 5 SIGN-BAND 864 × 230 mm Qty 1 Sign
• 7 BRACE-1 864 × 100 mm Qty 1 Carcass
• 7 BRACE-2 864 × 100 mm Qty 1 Carcass

Sheet 2 of 2

1 parts on this sheet. They cover 5.9% of a 1220 × 2440 mm sheet. Cut path 2.26 m. About 23 min at the typical diode estimate (best 19 min, slow 34 min).

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• 6 SHELF-4 864 × 200 mm Qty 1 Shelf

Build stages

1. 1

   Cut the sheets about 207 min (3 h 27 min)

   Fit-test coupon first (slot = tab + 0.1 mm); cut 2 sheet(s): 31 m of path. Replace the logo placeholder in sheet 1 (CUT layer) with the customer artwork: keep every letter island tied with a 3 mm bridge. Inside-out order, air assist on.

2. 2

   Remove char and sand about 60 min (1 h)

   Brush off the char, 120 then 180 grit; ease the shelf front edges and the logo opening. Wipe clean.

3. 3

   Dry fit about 20 min

   Lay SIDE-L flat, push the 4 shelves, 2 braces and the sign band into their slots, add SIDE-R. Check the tab ends are flush and that the unit stands without rocking.

4. 4

   Finish all parts flat about 60 min (1 h)

   Oil or poly all faces and edges flat (fast), mask the tab and slot surfaces only if you want them to be glued later. Brand colour or stain on the sign band if ordered.

5. 5

   Test-assemble with screws about 20 min

   NO GLUE: it is knock-down. Drive 12 #8 x 1-1/2 in screws (3.0 mm pilots pre-cut) through the side faces into the shelf and brace edges. Re-removable for flat storage.

6. 6

   Stability check about 15 min

   Tip test with every shelf loaded (see the load rating): it must not tip at a 10 deg lean. Fit the 2 anchor holes in the sign band with a wall strap or hang a 5 kg ballast bag on the bottom shelf for outdoor use.

7. 7

   Knock down and flat-pack about 25 min

   Unscrew, stack the 4 shelves, braces and band between the two sides with cardboard spacers, add the screws in a labelled bag and the 1-page assembly sheet; 1.5 m x 0.5 m x 0.2 m box.

8. 8

   Customer assembly (about 10 min) about 10 min

   Customer lays one side flat, slides in shelves and braces, adds the second side and drives the 12 screws with a Phillips/Torx driver. No glue, no clamps.

About 6 h 57 min for all 8 stages.

Materials and hardware

18 mm (3/4 in) Baltic-birch or birch plywood, 4 x 8 ft x 2 (paulownia/light ply for carry-friendly sets). Thickness 18 mm. 2 sheets.

Glue: Titebond III, about none (screw-together).

Finish: water-based poly or hardwax oil; stain or paint the band in brand colour (about $14).

Screws counted from the model: #8 x 1-1/2 in × 12.

Profit estimate

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.

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).

Selling price, at the typical diode time

ESTIMATE: 2.3 h (low-speed case 4.9 h, best case 1.4 h) of machine time per unit for 31 m of cut path in 2 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: Etsy/web listings $180-$1,100, four-tier A-frame ~$570; custom target $200-$800 (estimate)

Try your own numbers

Change the sheet cost, hardware, selling price, labor rate, or machine time. Finish ($14.00) and packaging ($22.00) 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 2.2 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.

Safety notes

• Target load per shelf 15 kg, bottom shelf 25 kg - UNVERIFIED; load-test one unit.
• Tall and shallow at the top: strap to a wall indoors or add 5 kg ballast outdoors (wind). Do not let customers climb it.
• Keep heavy product on the bottom tiers; the top tier is for light items only.
• Not a children's product.

Unverified / to test

• Load rating and tip angle untested.
• Folding variant is not modeled (this is knock-down only).
• 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.
• Logo cut-out is a placeholder; customer artwork needs bridges for letter islands.
• Price band is an estimate from a survey of similar pieces for sale (the repeat B2B reorders are the draw, not a measured demand).

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