1. Innovation Space
Manufacturing Plan

2. Basic Wood Working PVC Connections Bamboo Joinery Universal Joint
Cost: $50
Tools:Ryobi Japanese hand saw, marking knife, layout square, sandpaper, clamp, chisels, brace and bit, drill bits, wooden mallet
Uses simple hand tools and a basic power jigsaw to cut female grooves and male connectors into wood for mortise and tenon, dovetail, dado and dowel joints
PVC Connections
Cost: $10-15 for pipes, $1-3 for connectors
Tools: PVC cutter, brace and bit
Uses pvc pipe, pre-made pvc connectors and simple hand tools to assemble pvc pipes
Bamboo Joinery
Cost: $20 for tools, $3 for rope
Tools: hand saw, hammer, file
Uses simple tools and rope to create bamboo joints
Universal Joint
Cost: $20 for tools, $5 for sheet metal
Tools: metal sheers, sheet metal punches, hammer
Uses sheet metal working tools to hand mold a connector that can be used to connect things
Structures
Metal to Wood –Bracing and trusses
Strawbale—Pin Joints
Mud Bricks
Odds and Ends Joints
C-Clamps
Tie-Wraps

3. How We Build
Methods for building in the Innovation Space with limited power tools and skill sets

4. Basic Wood Working Cost: $50
Tools:Ryobi Japanese hand saw, marking knife, layout square, sandpaper, clamp, chisels, brace and bit, drill bits, wooden mallet, block plane, waterstone
Uses simple handtools and a basic power jigsaw to cut female grooves and male connectors into wood for mortise and tenon, dovetail, dado and dowel joints

5. Basic Wood Working
Pros: wood is locally available, very sturdy structures, easy to cut
Cons: requires a lot of skill for certain joints, time consuming
Mortise and tenon joint (top right picture ‘A’)
Tenon – rectangular protrusion from the male joint
Mortise – female joint with a square opening
Measure and mark the tenon; use the saw and chisel to cut
On the female joint, measure and mark where the mortise will be
With the largest drill bit, drill through the center of the mortise square and use a chisel to square the rest of the piece
Fit the tenon in the mortise; drill a hole for the dowel on the protruding portion of the tenon
Hammer the dowel the hole to secure the tenon in place

6. Basic Wood Working
Pros: wood is locally available, very sturdy structures, easy to cut
Cons: requires a lot of skill for certain joints, time consuming
Sliding Dovetail joint (top right picture ‘B’)
Mark and measure the dovetail; a taper of 3-5 degrees is recommended
Cute the dovetail and sand it until the edges are rounded and smooth
To cute the dovetail groove, clamp the dovetail to the female joining piece and use it as a guide for the saw; cut
Chisel the groove and sand until the dovetail fits securely

7. Basic Wood Working
Pros: wood is locally available, very sturdy structures, easy to cut
Cons: requires a lot of skill for certain joints, time consuming
Dado Joint (top right picture ‘C’)
Measure and draw the groove cut length wise on the mating piece
Cut each side of the groove ¼- 1/2 inch down
Use a hammer and chissel to remove the wood for the groove
Hammer the joining piece in place

8. Basic Wood Working
Pros: wood is locally available, very sturdy structures, easy to cut
Cons: requires a lot of skill for certain joints, time consuming
2. Dowel Joint (top right picture ‘D’)
Measure and draw the spacing for the dowels on both pieces that are to be joined
Drill half the length of the dowel down on each side
Hammer the dowel into the holes on one piece
Match up with the joining parts holes, hammer in place

9. PVC Connections Cost: $10-15 for pipes, $1-3 for connectors
Tools: PVC cutter, brace and bit
Uses pvc pipe, pre-made pvc connectors and simple hand tools to assemble pvc pipes

10. PVC Connections -Pros: initial low cost, light weight
-Cons: not as durable as clay piping
1. The first step is to apply the primer to the fitting and pipe ends. The PVC Primer will soften and prepare the PVC Fitting or PVC pipe length for the cement that will be used when connecting.

11. PVC Connections -Pros: initial low cost, light weight
-Cons: not as durable as clay piping
2. Next, choosing the cement may be the most important step in the process. Before applying the cement, you need to stir it well.

12. PVC Connections -Pros: initial low cost, light weight
-Cons: not as durable as clay piping
2. After stirring, liberally apply it to both the pipe end and fitting socket. Add one more layer of cement to the pipe end, and then quickly assemble the fitting and pipe, ensuring a full and complete connection. Finally, wipe away the excess and let it dry

13. Bamboo Joinery Cost: $20 for tools, $3 for rope
Tools: hand saw, hammer, file
Uses simple tools and rope to create bamboo joints

14. Bamboo Joinery: How To Basics
Pros: environmentally benign, sustainable, available locally, durable, seismic resistant, easy to cut
Cons: circumference variations makes joining difficult, no standard in universal joinery that is strong and affordable
Identify nodes – thick rings; these are needed for both ends of the joints or else the bamboo will splinter
bamboo joint node

15. Bamboo Joinery: How To Basics
Pros: environmentally benign, sustainable, available locally, durable, seismic resistant, easy to cut
Cons: circumference variations makes joining difficult, no standard in universal joinery that is strong and affordable
Similar to tube fitting (this bicycle frames), bamboo joint cuts have a male cut that fits into a female groove on the connecting piece
bamboo male cuts

16. Bamboo Joinery: How To Basics
Pros: environmentally benign, sustainable, available locally, durable, seismic resistant, easy to cut
Cons: circumference variations makes joining difficult, no standard in universal joinery that is strong and affordable
Cord or a dowel system (above left inset) can be used to secure the joint; wood nails will splinter the bamboo
Securing a bamboo joint

17. Universal Joint Cost: $20 for tools, $5 for sheet metal
Tools: sheet metal shears, sheet metal punches, hammer
Uses sheet metal working tools to hand mold a connector that can be used to connect things
NCIIA Cameroon Project
Leslie Speer, San Jose University
"Reverse Engineering Bicycles to Develop New Businesses, Products and Increased Income for the Metalworking and Agriculture Industries in Lebialem (Cameroon)".

18. Universal Joint Cost: $20 for tools, $5 for sheet metal
Tools: sheet metal shears, sheet metal punches, hammer
Uses sheet metal working tools to hand mold a connector that can be used to connect things
1. Cut shapes out of sheet metal with metal sheers and punches (drawings can be found at )
2. Hammer sheet metal to shape of connector

19. How We Connect
Methods and options for connecting similar materials, mixed materials and hardware to projects in the Innovation Space

20. Simple Structures Mud bricks shaped with wooden molds Dries in the Sun
Clay+Straw+Water (simple materials)

21. Sand and cement mixture
Straw Bale
Straw and soil mortar
Sand and cement mixture

22. Blocks Pinned together Attach around secured pole
Straw bale Connection
Blocks Pinned together
Attach around secured pole

23. Woodworking: Pegs
Uses:
Furniture
Vehicles
Small Structures

24. Metal Joints: Trusses Metal->Wood connections

25. Simple Mechanisms: Materials to Material
C-Clamp
Tie-Wrap

26. “Usables”: Materials to Hardware
Casters
Bolt and Lock Nut
Casters have four pre-drilled holes around it’s top support. They can easily attach to a flat surface using bolts and nuts.
Non-swivel wheels can attach using a bolt, spacer and lock nut assembly.

27. “Usables”: Materials to Hardware
Surface Mount Hinge
Mortise Mount Hinge
Attached to the door or frame; uses screws to secure
Mounted into recessed cutouts (mortises) on door's edge; uses screws to attach
Reference: mcmaster.com

28. “Usables”: Materials to Hardware
Eyebolts to Hooks
Eyelbolt to Rope
An eye bolt screw could provide an easy connection to a carabineer style hook for a removable item, such as a bag that fits into a cart or to secure an item onto a cart
A simple way to secure items on a cart would be to attach an eye bolt to the frame of the cart in appropriate locations and use rope to secure it in place
Reference: mcmaster.com