Parametric Wall Art Panel "Serenity"

I made a parametric wall art panel. I called it Serenity.

I fell in love with this style a few years ago when I first saw examples of parametric furniture. And it's not my only parametric design work to date.

Supplies

I don't remember how, but I got a file with a 3D model of this panel. I myself, unfortunately, do not know how to create 3D models and process them to create parametric models. Through 2-3 format conversions I managed to open this file in AutoCAD. I was able to extract and convert all 60 parts that make up the panel for printing. I printed each piece on 3 A4 sheets, glued them together according to the markings, numbered each strip (80 cm long) and cut out along the contour. Now I was ready to go to my workshop.

For this project I used:

1. 10 mm plywood - 6 to 6.5 square meters

2. 2x2 cm birch slats - 2.5 meters

3. Wood glue

4. Wall holders - 2 pcs.

5. Separating plates made of 3 mm fiberboard - 180 pcs.

Of the tools I used:

1. Electric jigsaw.

2. Manual milling machine

3. Engraver with a sanding head

4. Table saw

5. Nail gun

6. Grinder

7. Cordless screwdriver

8. Clamps and a tightening strap

9. Pneumatic paint sprayer

Step 1: Preparation of Templates

So, first, I cut 2 sets of 60 rectangular blanks from plywood according to the width of each part (one set for the templates, the other for the panel). Then, on one set, I manually traced the outline of each part from the paper blanks. Then with an electric jigsaw with a fine saw I cut all the parts according to the contour. In some places the cut was not perfect and the plywood burned at sharp turns. I didn't care about the chipping in some places, since I was making templates for the router.

To satisfy my inner perfectionist, I cleaned off all the burnt areas with an engraver, and also trimmed all the radiuses on the curves. I also outlined the areas where cutouts would be made for the support rails. Drilled and countersinked holes for screws in the center of those areas. The templates are ready.

Step 2: Production of Finishing Parts

When the templates were ready (I made them in case I had to make another one of the same panels), each was screwed to the workpiece from the second set. The back wall of the panel is straight, so there were no problems with the alignment of the template. After mounting a regular hand router on the router plate, I secured it to a folding workbench. And cut out all 60 finishing parts perfectly using the templates. 

Then in the sliding table saw carriage I mounted the part stops and cut three 2 cm wide and 2 cm high slots in each part from the back side. After that was sanding. Lots of sanding. I put the clean parts together in order and the overall appearance of the panel began to emerge. 

Also on the scraps of plywood applied several coating options. I decided on a dark brown color.

I used a paint gun to paint all the parts and mounting rails with the first coat. With a 100 grit sponge I removed the raised lint.

Now the panel is ready to be assembled.

Step 3: Final Assembly and Coloring

First, I cut 180 spacer plates from 3 mm thick fiberboard for gaps when mounting the parts. Next, I glued the support rails and put the parts on them, alternating with the spacer plates, which were simply inserted between the parts to maintain the same gaps. I fixed all the elements between them with two clamps and a tightening strap. On the reverse side, at each point of contact between the parts and the carrier rail, a nailer added staples for better adhesion. 

The next day, after the glue dried, I trimmed off the excess support rails on the sides and painted the ends.

Then I sprayed a finishing coat of paint and, after it dried, I applied a coat of varnish.

I screwed two wall mounts onto the top carrier rail. 

Done.

Step 4: Finished Panel

The length of the pattern was 78 cm. The 60 pieces of 10 mm plywood and 59 3 mm spacer plates combined gave the panel width of 78 cm as well. 

As a result, the size was 78x78 cm and the weight of such a panel was 13 kg. 

Now it decorates our bedroom.

Thanks for your attention.