Creating Laminating Base - V3 - Cardboard Support

Proven

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

Cardboard Wedges	Cardboard Stabiliser

Cardboard Stabiliser In Place	Cardboard Support Final

Time needed

Type	Hours
Implementation	0.75 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
Thick cardboard Consumable Cardboard sheet used to form a base	1 sqm	Inexpensive
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			£16.00

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 sheet).

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

   • From cardboard, cut about 12 triangles angled at 27 degrees, long enough to support the footpocket section
   • Join the supporting triangles with a horizontal cardboard stabiliser strip to keep them in place
   • Place the cardboard wedge under the footpocket section and secure in place with a bit of tape

Benefits

• Apart from the sheets, the materials are inexpensive
• 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.