Creating Laminating Base - V2 - Plastic Wedges

Legacy

Goal

Provide a modular surface with adjustable wedges to support blades during lamination.

Specifications / Dimensions

• Target working area: ~60 × 90 cm
• Purpose: Provides enough surface for a two long fins plus sealing margin
• Support requirement: Must be placed on a flat, rigid surface such as a table or workbench
• Protection: Place a plastic sheet under the base to protect the table surface

Reference Images

Stackable Wedges Pack	Stacked Wedges

Angled Base Desired Angle	Stacked Wedges Support

Time needed

Type	Hours
Implementation	0.5 h
Waiting	0 h

Bill of Materials

Material	Quantity	Unit Cost	Line Cost
Acrylic sheet (A3, 2 mm) Reusable Six panels for laminating base	1 6 pack A3 sheet (2 mm)	£16.00 per 6 pack A3 sheet (2 mm)	£16.00
Stackable plastic wedges Reusable Adjustable supports for the angled foot pocket section	1 pack (18 wedges)	£7.00 per Pack of 18 wedges	£7.00
Protective plastic sheet Consumable Disposable sheet to protect the bench surface	1 sheet	Inexpensive
Electrical tape roll Consumable Wide PVC tape to join acrylic seams	1 roll	Inexpensive
Total			£23.00

Tools Required

Tool	Purpose
Isopropyl alcohol	Clean acrylic edges before applying tape
Scissors	Cut materials like fabric, film, or templates to size
Tape measure	Check dimensions and spacing during setup
Protractor	Measure angles

Instructions (step-by-step)

1. Prepare the surface

   • Place a plastic sheet on a flat, rigid table or bench.
   • Ensure there is no dust or debris under the plastic.

2. Arrange acrylic sheets

   • Flat blade section: 4 A3 sheets in a 2 × 2 layout (~59 × 84 cm).
   • Footpocket section: 2 A4 sheets side by side - cut one A3 in half (~29.7 × 84 cm).

3. Join sheets

   • Clean edges with isopropyl alcohol.
   • Bridge each joint with electrical tape
   • Press tape firmly to remove trapped air and keep surface flush.

4. Add wedge supports

   • Stick the wedged together using the double-sided tape until you achieve the target angle, typically 20–30°
   • Place plastic stackable wedges under the footpocket section.
   • Ensure wedges are stable and evenly distributed.

Benefits

• This version does not require a heavy wooden support structure, making it much easier and faster to put together.
• Modular design — acrylic sheets and wedges can be stored flat and reused for different versions.

Limitations

• The base cannot be placed as a whole into a vacuum bag.
• The only viable vacuum method is sealing the edges of the bag around the acrylic surface, which is less flexible than a solid one-piece base.