Summary

A single sheet of polypropylene folded to create a 450mm-high stool. Intended for use in a design studio or around any low table/desk.

Instructions

Things you will need:

ShopBot
3mm end mill (down-spiral)
6mm ball nose mill
3mm thick polypropylene (at least 1200mmx1200mm)
sacrificial MDF board (I used a 3mm thick sheet)
plenty of double-sided tape
screws/drill (for securing MDF)

Step 1 - Secure sacrificial sheet by hand(preferably MDF - something cheap) to the Shopbot with screws around the edge. Ensure it's completely flat.

Step 2 - Fix 6mm ball-nose and run 'Drill' drill path once axes have been established. Drill additional screws into these points.

Step 3 - Stick PP sheet to MDF with double-sided tape (the more the better - and you may need a hand with this).

Step 4 - Run 'Scores' cutting path with 6mm ball-nose still in place, at 2.5mm cutting depth.

Step 5 - Change to 3mm end-mill (remember to reset set z-axis). Cut 'Profile Cuts' file, at 3.7mm cutting depth.

Step 6 - Remove cut, clean edges/scores.

Step 7 - Follow diagrams to fold form - firstly folding the top faces with the scored edge facing out. Then the remainders with the scored edge inside the fold.

Note: - all cuts/scores are made with a spindle speed of 5000rpm, with feed rate set at 20mm/sec and plunge rate at 10mm/sec (refer screenshots).

Cutting time should take around 20 minutes.
Partworks file attached should you want to make any alterations

'Gyu' Polypropylene Stool