Manufacture Flowchart

START

Measure the length, width and height of a passport, wallet, cash, and use own measurements for jewellery and miscellaneous objects cavities

Make molds using MDF for the lower cavity and 1mm thick card for the upper cavity which will have a larger height and width. Make upper cavity 2mm. The molds have to fit within 302 mm x 422mm

stick 2mm card on MDF on the top part of the bottom cavity using gluestick

Vacuum-form HIPS sheet using molds

Do all objects fit perfectly?

Make bottom cavity thicker using card stuck on top part of bottom cavity

Cut any unused plastic of HIPS sheet to measure 312 mm x 422 mm

add 10mm to the height and width of HIPS sheet which should make 322 mm x 432 mm

cut a pinboard and laser-cut white opaque acrylic to measure 322 mm x 216 mm each

cut 12mm thick ash planks to get 2 frame parts that measure 474.5 mm and another 2 to measure 346 mm

Cut rebates into the wood at a depth of 5 mm. The first rebate is 10 mm wide after 6 mm is left. Cut a 3mm wide rebate after 16 mm.

Use a mitre saw to cut the wood planks at an angle of 45°

For the longer pieces, does the inner part measure 442.5 mm?

For the shorter pieces, does the inner part measure 314 mm?

Cut a 422 mm piece from right in the middle of the top piece of frame. The width should be 15 mm and it should be exactly at the back of the frame.

Glue everything together excluding the wood cut-out.

cut 10mm thick PVC for the top cavities

melt the PVC sheet into the HIPS sheet using a pyrography pen; the PVC sheet prevents the objects from falling out.

sand the PVC sheets and the HIPS sheet to make the edges and sides smooth

cut a strip of wood which has a length of 422 mm and a height and width of 10 mm

stick the strip of wood to the frame cutout

use small nails to nail the HIPS sheet onto the wood strip

Does the HIPS sheet touch the bottom part of the fram

add small wood pieces to close the gap

laser cut a design to use as a wall mount into 2 wood pieces with a width of 3mm

stick 2 edges of each laser-cut wood piece into the 3mm wide rebate at the back of the frame in the top 2 edges of the frame

END