The cut sheets
1 sheet. 1220 × 2440 mm, 18 mm plywood. Total cut path 36.0 m.
Machine time for the whole unit: about 1.3 h best, 2.4 h typical, 5.4 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 1.1 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
-
1
Cut the sheet(s) about 240 min (4 h)
Run the fit-test coupon (slot = tab + 0.1 mm), then cut 1 sheet(s) from the DXFs (CUT layer): 36 m of path, 33 slotted vents in the shelves. Inside-out order, air assist on.
-
2
Remove char and sand about 55 min
Brush the char from every cut edge, 120 then 180 grit; ease the seat edge to a 3 mm round-over by hand; sand the vent slots with a folded strip of paper.
-
3
Dry fit about 15 min
Stand the SIDES, slide in the 2 SHELF board(s), dividers, RAIL-TOP, then the SEAT. Check tab ends are flush and the case is square; no glue.
-
4
Pre-finish about 45 min
Seal all faces now (poly or hardwax oil) - shoes are wet and dirty. Mask the tabs and slots so the glue still bonds.
-
5
Glue-up (Titebond III) about 30 min
Glue the dividers into the shelves, then the shelves into SIDE-L, add SIDE-R, RAIL-TOP, and finally seat the SEAT over all top tabs. Clamp across the width; wipe squeeze-out.
-
6
Screws as clamps about 20 min
6 #8 screws (3.0 mm pilots pre-cut): #8 x 1-1/2 in through the side faces into the shelf edges and down through the seat into the side edges (hidden under the frame); then 6 x #8 x 1-1/4 in down through SEAT-RIM into the seat.
-
7
Cushion frame about 15 min
Glue and screw SEAT-RIM on the seat (covers the tab ends). The recess holds a cushion up to about 45 mm thick, size = opening printed on sheet 1. Cut the cushion board from the offcut if wanted.
-
8
Optional cleat / wall hang about 20 min
For a floating SHOE SHELF version only: Z-bar cleat on the rear face of RAIL-TOP into studs. Do not use as a seat when wall-hung unless every cleat screw is in a stud and the wall half is rated (unverified).
-
9
Finish, load test, pack about 40 min
Final coat on the seat, 24 h cure, sit-test with 120 kg, felt pads on the 4 feet, flat-pack in one box with corner guards.
About 8 h for all 9 stages.
Materials and hardware
18 mm (3/4 in) sanded plywood (basic birch-faced or cabinet ply), 4 x 8 ft x 1; use hardwood ply for a premium version. Thickness 18 mm. 1 sheet.
Glue: Titebond III, about 3 oz.
Finish: water-based poly (wet-area rated), 2 coats (about $9).
| Hardware | Qty | Each | Line |
|---|---|---|---|
| #8 x 1-1/2 in wood screws from model | 6 | $0.06 | $0.36 |
| #8 x 1-1/4 in wood screws frame to seat | 6 | $0.06 | $0.36 |
| Aluminum Z-bar cleat pair optional, shoe shelf only | 1 | $12.00 | $12.00 |
| Seat cushion 1-2 in foam + cover (optional, sold separately) customer or add-on | 0 | $0.00 | $0.00 |
| Felt/rubber foot pads | 4 | $0.40 | $1.60 |
| Wood plugs | 1 | $2.00 | $2.00 |
| Hardware total | $16.32 |
Screws counted from the model: #8 x 1-1/2 in × 6, #8 x 1-1/4 in × 6.
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 | 1.31 h | 2.36 h | 5.4 h |
| Cost per unit | $102.55 | $104.33 | $109.50 |
| Gross margin | $117.45 | $115.67 | $110.50 |
| Gross margin % | 53.4% | 52.6% | 50.2% |
| Net after fees and labor | $45.45 | $43.67 | $38.50 |
| Gross profit per machine hour | $89.66 | $49.01 | $20.46 |
| Net profit per machine hour | $34.70 | $18.50 | $7.13 |
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 | 1.09 h | 0.29 h | 0.19 h |
| Cost per unit | $109.04 | $102.64 | $101.84 |
| Gross margin | $110.96 | $117.36 | $118.16 |
| Gross margin % | 50.4% | 53.3% | 53.7% |
| Net after fees and labor | $38.96 | $45.36 | $46.16 |
| Gross profit per machine hour | $101.80 | $404.69 | $621.89 |
| Net profit per machine hour | $35.74 | $156.41 | $242.95 |
Selling price, at the typical diode time
| Low price | Mid price | High price | |
|---|---|---|---|
| Selling price | $140.00 | $220.00 | $300.00 |
| Cost per unit | $104.33 | $104.33 | $104.33 |
| Gross margin | $35.67 | $115.67 | $195.67 |
| Gross margin % | 25.5% | 52.6% | 65.2% |
| Net after fees and labor | -$28.33 | $43.67 | $115.67 |
| Machine hours | 2.36 h | 2.36 h | 2.36 h |
| Gross profit per machine hour | $15.11 | $49.01 | $82.91 |
| Net profit per machine hour | -$12.00 | $18.50 | $49.01 |
ESTIMATE: 2.4 h (low-speed case 5.4 h, best case 1.3 h) of machine time per unit for 36 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: custom target $140-$300 (estimate); Amazon typical ~$75, Etsy $129-$190 [third-party estimates]
Try your own numbers
Change the sheet cost, hardware, selling price, labor rate, or machine time. Finish ($9.00) and packaging ($10.00) 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 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 | 1000 | 600-1400 mm (2 dividers over 1000) |
| Height | 450 | 380-520 mm |
| Depth | 400 | 300-480 mm |
| Thickness | 18 | 17.5-19 mm |
| Slot clearance | 0.1 | 0.0-0.2 mm |
| Plinth height | 90 | 90-150 mm |
| Shelves | 2 | 1-3 (bay >= 120 mm) |
| Dividers | 1 | 0-2 |
| Cushion recess | 1 | 0 or 1 |
| Slatted shelves | 1 | 0 or 1 |
| Cleat | 1 | 0 or 1 |
Safety notes
- Seat load rating target 120 kg (265 lb) - UNVERIFIED, load test every design change (sag test at the seat centre).
- The center divider(s) carry the seat; do not omit them on benches wider than 800 mm.
- Wall-hung (cleat) use: shoe shelf only unless studs and a rated cleat are used.
- Not a children's product (no CPSIA testing).
Unverified / to test
- Seat strength and deflection untested (18 mm ply over 1000 mm without dividers would sag about 12 mm at 100 kg by hand calculation).
- 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.
- Cushion fit depends on the cushion bought.
- Composite decking top is a CNC-only variant, not modeled here.
- Price band is an estimate from a survey of similar pieces for sale.
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.