Tambour Puzzle Table

My long term project was a puzzle table with a wooden tambour cover. The puzzle table that is used daily at my house is constantly covered with a blanket to prevent pieces from falling off or it getting ruined by our cats. This inspired me to make a puzzle table that you could easily place a cover over without it taking up extra room. Comparing it to my table at home, I designed it based off this with numerous upgrades. Such as bigger drawers, a cover, and notches that allow it to sit on top of our current coffee table without sliding around. I created this project using the CNC router and 3D printer for various parts.

Tools:

1. CNC Router
2. 3D Printer
3. Nails (or staples)
4. Screws
5. Scissors

For my first step, researching, I looked into different types of making a cover for the puzzle table. I decided on tambour due to its efficiency with space and how easily it could be moved to cover the puzzle. I looked into different types of tambour and what elements would be needed for the table, such as being used as a cover while also being strong enough to be used as a coffee table.

After looking at different styles of tambour, I found someone(Simone Giertz) who made a project similar to mine but more complex. I watched her video numerous times, and reflected back to it when confused, to figure out the final details of what I wanted my personal table to look like.

For my step 2, I created a CAD Design of the full puzzle table and of individual parts, to see my project in 3D so that I would be able to conceptually think about the design. I struggled making it for awhile as I wasn't sure what I wanted my table to look like as I wanted it to be different from Simone Giertz's but also have similar features. Above are examples of the individual parts and the demensions that correlate to the dimensions of my coffee table at home so that it will be able to attach without sliding around or easily being pushed off.

After 3D printing a prototype of my design and analyzing the youtube video of Simone Giertz's puzzle table, I realized a few features that I needed to change for it to function as a table efficiently. I updated how the tambour would go around the table by removing two of the sides to allow it to make a wider curve. I changed the inside of the table and added sides to the puzzle top so that puzzle pieces wouldn't accidently slide underneath the table and become inaccessible. My final change for my redesign was to change how the tambour pieces, wooden slats, would fit together. All these updates to the original design will make the manufacturing process easier while also keeping the project functional and similar to the original concepts and goals.

While I've only completed a few of these steps, the process can be easily completed and repeated after creating the first step, being manufacturing the side table parts.

To manufacture this the table, I used the CNC Router to cut out the two sides of the table that have more intricate details. First create and design this part, I used CAD and CAM so that the parts were developed correctly to be cut out on the router. The other wooden parts, such as the drawer pieces(4 sides and bottom), the wooden slats or tambour pieces, and foot holds(to attach the puzzle table to a coffee table) can be cut out using a bandsaw or table saw. After that you can place your chose type of wood on the router and upload your model so that it can be made.

Then you will need to design and create, using CAD, a gear that allows the tambour pieces to move as one by the nubs going into slots at the ends of the wooden strips so that they are pulled along when being rotated by the metal knob. After making this part with the specific dimensions for the wooden slats, metal bar, and metal knob, you can upload it onto a USB then onto a 3D printer to be printed out and made.

The wooden slats that allow the table to have the tambour feature can be manufactured through different steps. The first step is to use a table saw or bandsaw to cut the strips into the required sizes. Next, if you had the needed router bits, you would create the rounded interior and exterior parts on each side of the pieces. Finally, you would use a drill with a .25" drill bit to create the gap on the end of the slat, for the gear knob to fit into and be used to pull around the table.

After or during that, you will need to purchase additional parts for the table. Two metal bars, will need to be bought, that will connect each side of the sides so that the wooden slats and metal knobs(also bought) move as one on either side. Four metal knobs will also need to be purchased which will allow the tambour cover to be moved or slide underneath the table. This will prevent the wooden slats from getting stuck or being unable to slide around by simply being pushed.

When onto the step of assembly...

You would first need to gather all the wooden slats or strips and place them to that they all fit together to create two different covers. These two covers will fit together to create the top but separate when the knobs are turned to go underneath the table from either side. After they are all fitted together, lay out the cloth or fabric that will be used to make sure the pieces stay together. After cutting the fabric to size, nail or staple the fabric into place on either end of each slat (there should be 15 tambour strips for each section of the cover).

After creating the tambour features, screw the knobs, gears, and metal bars to the sides of the table. This will be the beginning of putting the table together as a whole. After completing this task, place the tambour feature into either side of the table and nail or screw the sides of the table, the wooden foot holds, and two additional wooden strips between the two sides together. After completing this segment, the table will be mostly complete except for a few features.

The final parts to assemble are the drawers that slide inside the table and place the assembled puzzle top into the table. Each of the pieces for the drawers can be assembled using wood glue and nails. Once this is done, slide the drawers into place inside the table. Place sides onto the puzzle top using a similar step as for the drawers, using nails and wood glue, to finish the puzzle top. Use the metal knobs to open the tambour segments then place the wooden puzzle top into the table. After this is completed, the puzzle table is finished and assembled.

Throughout this process of designing and manufacturing the tambour table, I have learned that it is required to fully create each component in CAD so that a 3D image and well thought out design can be created. Without all of the components, the interior parts of the table, such as the gears, can get confused and lost in the manufacturing process. I struggled to starting the manufacturing process and have learned that it isn't necessary to start on the hardest part or allow one component to stump the whole project. Completing what you can of the project should be your first priority and gaining any progress on any step in the project is helpful. When improving this project, or remaking it, I would start building my CAD model with the end design that I wanted to I would be able to see all components come together. As well, I would 3D print out the moving parts, such as the gear, slats, rotating bar, and turning knob to be able to see how they fit together and if they are able to function accurately at the size I plan to manufacture them at. Overall, I struggled with beginning the manufacturing step of the process but excelled creating a well thought out and designed product, so if I am ever able to I can restart, and finish, this project knowing exactly what to do next.