Newbie- Advice Needed for Home-based Business Idea

[jphakala]

I am thinking about starting a home-based business that manufactures ABC wooden block sets for kids. I am researching computer controlled routing machinery that can carve out alphabet letters from 2-inch by 2-inch wood blocks. I know very little about computerized routing systems and would like the least amount of set-up as possible.

Do CNC cutting systems exist that will cut all six sides of the wooden block or will I need to set-up manually for each cut? Can I set-up/clamp multiple blocks and have one surface cut (same or different letters), then rotate the wooden blocks and set up, then cut the other surfaces, etc, until all six sides are done?

Can anyone direct me to information sources on this subject and the CNC machinery options that are available? What is the range of costs for setting up this system?

Thank you for your advice.

John Hakala
Eagle River, Alaska
jphakala@alaska.net

[ger21]

You'll find that holding the blocks while cutting them will be the tricky part, and having to do all six sides will probably take longer than you think. I'd probably try using long 2x2 stock, and cutting multiple block faces out of each side, rotating it 4 times, then cut it into the blocks, and finish the other 2 sides. You'll want some type of clamping system to hold multiple blocks at a time, to speed up production.

Assuming you don't want to build your own router, I'd look at www.k2cnc.com and www.romaxxcnc.com. Expect to spend at about $3000 on a machine (for a small one) and $500-$1000 on software to get started.

[wcarrothers1]

Then you have to figure what will make your wooden blocks be different then the ones that come from china. (other then it would be interesting to have blocks made in Alaska)..

Like do some sides have pictures of somthing from alaska that starts with that letter?

b.

[CarveOne]

Instead of working with so many individual blocks, why not work with properly sized square sticks that can be routed on each of the four sides, then cut apart on a band saw and sanded smooth on a disk sander. Then stack the blocks between wood clamping strips and route the remaining two smooth faces. The clamping strips could have holes in them for machine screws in between the blocks to provide even clamping of each block and provide consistent spacing. The CAD drawing and resulting gcode file would need to be adjusted for the proper spacing to compensate for the saw kerf and light sanding when cutting the stick, and for the screw diameter spacing of the individual blocks.

Sounds like this could be an interesting product idea. For the kids, you need to stick with the approved woods and paints for safety. For art objects you can use any type of wood including laminated exotic woods, some plastics, even the recycled plastic "lumber" material.

CarveOne

[ger21]

Originally Posted by CarveOne then cut apart on a band saw and sanded smooth on a disk sander.

Sanding end grain smooth is very difficult, especially since you'll be (most likely) using a hard wood like maple. A good blade on a table saw with a cutoff sled will give you glass smooth cuts with no sanding needed, in a fraction of the time.

[cabnet636]

we have been awarded a job to produce panels to cover the lighting switches in a hotel chain, these were vcarved with the logo on on side and the switch locations on the other, i saw a jig where the pieces were inlayed into an mdf cutout on another forum and used this method, worked perfect did 12 on one side flipped them and did 12 on the other!! now after this they want humidor type boxes for the guest rooms.


jim

[jphakala]

Thank you all for your excellent advice. I was sharing my "idea" with our three teenagers after dinner last night. Their eyes rolled..."are you going to be like those old guys selling wooden toys at the fair?" I explained the manufacturing processes and demographics and they became more interested. They liked it when I asked them about becoming shareholders in the company...but became less interested when I suggested that they donate their college funds for start-up costs. Was just joking with them of course and won't plan on leaving my day job just yet. - John Hakala

[Big S]

Sounds like an idea, If you have a CNC there is a world of things you are able to make with it if the blocks don't work out.

Shannon.

[low_48]

Just generally thinking about your idea. It might be an interesting tourist sell if you have routed profiles of salmon, bears, eagles,etc..... on the sides opposite the letters. If you made them specific to Alaska, the market might be there to compete with China. Oh yeah, don't forget to put the pipeline on some, and the Valdez, and the oil wells.......LOL

[Torchhead]

Customers/buyers will pay more for any item that is:

Unique and detailed
Personalized

They will also spend money to their kids and hobbies. Horse stuff sells well in the warmer part of the US. Other things break into "communities of common interest" and offer the vendor a way to market a specific product to that community that they can't buy in a gift shop off the shelf.

The cheap blocks are probably stamped in lightening fast machines and turned out in the thousands per hour. Even a block with a unique design may not bring a lot more, but put the kid's name on one face, then you have something the Chinese can't offer!

Once you can do the blocks you can do dominos, and desk art type stuff etc. With CNC you can easily make one side custom/personalized and increase the value of your products.

I have experience competing with Mexico and decorative plasma designs. It became obvious early on that the superior finishes and cut quality of our designs were not enough to combat a price 1/2 or 1/3 of what we had to get. We beat them with unique designs and personalized/custom layouts.

If you get your art-to-part stream setup right and can do a design and cut file in a few minutes it becomes a lot more profitable!