The cut sheets
1 sheet. 1220 × 2440 mm, 18 mm plywood. Total cut path 27.9 m.
Machine time for the whole unit: about 1.1 h best, 1.9 h typical, 4.2 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 0.9 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(s) about 186 min (3 h 6 min)
Run the fit-test coupon first (slot = tab + 0.1 mm), then cut 1 sheet(s) from the DXFs (CUT layer): 28 m of path. Inside-out order, air assist on. The 1500 mm-class TOP and BOTTOM are the longest parts on the bed.
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2
Remove char and sand about 55 min
Brush char from the cut edges, 120 then 180 grit on faces and edges; ease the top corners. Wipe with a damp rag.
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3
Dry fit about 15 min
Stand SIDE-L and SIDE-R, push BOTTOM, the 2 divider(s) and both rails into place, then lower TOP over all the tabs. Check square and that TOP sits flat. No glue yet.
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4
Pre-finish the inside faces about 45 min
Seal / oil the bay faces and the rail faces before glue-up (mask tabs and slots so the glue still bonds). Two coats on all faces is easiest done flat.
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5
Glue-up (Titebond III) about 35 min
Lay SIDE-L flat. Glue and tap in BOTTOM, the divider(s), RAIL-BOT and RAIL-TOP, fit SIDE-R and clamp. Last, seat TOP on every tab with a few light taps from a block. Work in two halves if alone (10 minute open time).
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6
Screws as clamps about 20 min
10 #8 x 1-1/2 in screws (3.0 mm pilots cut in): through each side face into the BOTTOM edge, and down through TOP into the side and divider edges. Countersink and plug the top screws.
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7
Cable slots, TV strap, optional cleat about 25 min
Feed cables through the 3 rear slots. Fit the TV anti-tip strap through the 6 mm holes in RAIL-TOP into a stud. Optional wall-hung version: Z-bar cleat across RAIL-TOP into studs; heavy (rated load unverified), so only with a proper stud-rated cleat and an empty-console test first.
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8
Finish, test, pack about 45 min
Two coats of water-based poly or hardwax oil, 24 h cure, 40 kg weight test on TOP, felt pads under the 4 feet, flat-pack in one 1.55 x 0.45 x 0.15 m box with corner guards.
About 7 h 6 min for all 8 stages.
Materials and hardware
18 mm (3/4 in) birch or Baltic-birch plywood, 4 x 8 ft (1220 x 2440 mm) x 1. Thickness 18 mm. 1 sheet.
Glue: Titebond III, about 5 oz.
Finish: water-based poly or hardwax oil, 2 coats (about $16).
| Hardware | Qty | Each | Line |
|---|---|---|---|
| #8 x 1-1/2 in wood screws from model | 10 | $0.06 | $0.60 |
| Anti-tip TV strap kit TV to wall; recommended on every console | 1 | $8.00 | $8.00 |
| Aluminum Z-bar French cleat, 36 in pair optional wall-hung version, studs only; laser cannot cut the 45 deg bevel | 1 | $14.00 | $14.00 |
| Wood plugs / filler | 1 | $2.00 | $2.00 |
| Felt/rubber foot pads | 4 | $0.40 | $1.60 |
| Grommets for cable slots (optional) | 3 | $1.00 | $3.00 |
| Hardware total | $29.20 |
Screws counted from the model: #8 x 1-1/2 in × 10.
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 | 1.07 h | 1.89 h | 4.23 h |
| Cost per unit | $155.02 | $156.41 | $160.39 |
| Gross margin | $224.98 | $223.59 | $219.61 |
| Gross margin % | 59.2% | 58.8% | 57.8% |
| Net after fees and labor | $124.48 | $123.09 | $119.11 |
| Gross profit per machine hour | $210.26 | $118.30 | $51.92 |
| Net profit per machine hour | $116.34 | $65.13 | $28.16 |
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 | 0.86 h | 0.25 h | 0.17 h |
| Cost per unit | $160.08 | $155.20 | $154.56 |
| Gross margin | $219.92 | $224.80 | $225.44 |
| Gross margin % | 57.9% | 59.2% | 59.3% |
| Net after fees and labor | $119.42 | $124.30 | $124.94 |
| Gross profit per machine hour | $255.72 | $899.20 | $1,326.12 |
| Net profit per machine hour | $138.86 | $497.20 | $734.94 |
Selling price, at the typical diode time
| Low price | Mid price | High price | |
|---|---|---|---|
| Selling price | $240.00 | $380.00 | $560.00 |
| Cost per unit | $156.41 | $156.41 | $156.41 |
| Gross margin | $83.59 | $223.59 | $403.59 |
| Gross margin % | 34.8% | 58.8% | 72.1% |
| Net after fees and labor | -$2.91 | $123.09 | $285.09 |
| Machine hours | 1.89 h | 1.89 h | 1.89 h |
| Gross profit per machine hour | $44.23 | $118.30 | $213.54 |
| Net profit per machine hour | -$1.54 | $65.13 | $150.84 |
ESTIMATE: 1.9 h (low-speed case 4.2 h, best case 1.1 h) of machine time per unit for 28 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: My estimate: Etsy/web plywood media consoles roughly $200-$700 and Amazon 55-65 in particle-board units about $120-$250 (third-party, not verified here). A wall-fitted solid-ply console with cable slots and bays is priced above the commodity units; low = 1200 mm unfinished, high = 2000 mm finished.
Try your own numbers
Change the sheet cost, hardware, selling price, labor rate, or machine time. Finish ($16.00) and packaging ($18.00) 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 2.5 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 | 1500 | 900-2200 mm (bay <= 650) |
| Height | 480 | 380-600 mm |
| Depth | 400 | 300-480 mm |
| Thickness | 18 | 17.5-19 mm |
| Slot clearance | 0.1 | 0.0-0.2 mm |
| Plinth height | 100 | 90-150 mm (0 = floor standing) |
| Dividers | 2 | 1-4 (each bay <= 650 mm) |
| Cable slots | 1 | 0 or 1 |
| TV weight limit | 40 | 20-60 kg (hand calc only) |
Safety notes
- Strap the TV to the wall (anti-tip strap); a low console does not stop a TV tipping off it.
- Rated target 40 kg TV (88 lb) on the top, UNVERIFIED - load test one unit to 60 kg before selling; keep each bay <= 650 mm.
- Not a clothing-storage unit (STURDY Act applies to dressers >= 27 in); not a children's product (no CPSIA testing).
- Wall-hung (cleat) use only into studs with a stud-rated cleat; test empty then loaded.
- Keep AV gear ventilated: the open bays and rear slots are for that; do not box it in.
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.
- Top sag is a hand calculation (assumed ply modulus); a long span with a heavy TV needs a physical load test.
- Wall-hung cleat capacity of an aluminum Z-bar on a console this size is unverified.
- No doors or drawers are modeled; the TOP overhangs 20 mm on every side.
- Price band is my estimate, not a market quote.
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.