Manufacturing Guidelines

Contents

Introduction
Layout examples
DXF Layer Guide
Materials
-Finishing/Assembly
-Hardware/Fasteners
-Router Bits
Frontier System
Frontier Multi Plus +
Furniture (other)
Finishing
General Workshop

July 2020

Outpost Programme

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Introduction

Welcome to the Frontier Design Outpost Manufacturing guidelines. Before you

begin fabrication you should make yourself aware of the requirements of making,
selling and providing customers with great products.

We recommend making multiple test products before selling, allowing you to

understand each aspect of making, from CAD, CAM to assembly. The Frontier
Design Outpost programme works on the assumption that you not only have a
CNC machine but you are relatively experienced and skilled in furniture
fabrication and all that it entails. We do not take any responsibility for any
damage and/or faulty products, it is your responsibility to understand and put into
practise the information we provide.

All our files are supplied with 0 tolerance on joints. There are multiple ways to
offset material thickness eg via CAD and/or CAM, therefore we leave it at the
discretion of manufacturers to apply with their own ‘best practise’. If there is an
increasing demand via our forum for this to change (tolerance variations
provided). Then we will relook at this aspect. Of course any questions regarding
tolerances can be asked from your Outpost homepage (after login)

Our files for commercial makers are provided in .dxf form. Please see either our
blog or look further down on this document for more information how you should
interpret the file layers.

DXF files are provided in top projection form and layers are named after type and
depth of cut required.

Some of our dxf files (e.g Frontier System) are provided with layouts using either
25% 50% or 100% of a sheet of material. These types of product are more suited
to making a product to order. This allows you to maximise your workshop space
by not having large quantities of stock. We also have on some of our products
(e.g Multi Plus System) Full sheet layouts. Where the product have been broken
down into parts and laid out on a full sheet of material. This is to allow you to
make large volume production runs of products. It is also due to the fact that
several products in the Multi Plus range share common parts, which allows them
to fulfil several roles.

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Most furniture in our library should be cut ‘good' face down. In most cases this
will be the face that customers will be interacting with for example; table top,
chair seat etc…

Always follow standard CNC safety procedures before milling. If you don’t have
access to a vacuum table then carefully consider work holding of material (parts
may vibrate during fabrication).

Consider depth of cut and proper tooling. In our experience plywood has a higher
quality of finish when cut with multiple passes and slower speeds. It is however up
to each manufacturer to apply best practise.

Happy making, Frontier Design team.


3
 Layout examples



Kompis Desk
Gullig Stool

25% percent sheet layout 100% percent sheet layout

Standard Shelf Multi Plus +

Shelf full layout Shelf sides full layout Shelf full layout (long)

Note: The Multi Plus System is extremely versatile, with several shelf types sharing similar parts. Shelf
‘sides’ can be mounted to both long and short shelves. The idea was that parts should fulfil multiple roles.
Reducing the need for stocking large quantities for single purpose parts 4
DXF Layer Guide

Sketch layer:

TOP-CUT-INSIDE_8.000MM

Direction:

Pocket cut from the top of the material.

Depth of cut 8mm

Sketch layer:

TOP-CUT-OUTSIDE_18.000MM

Direction:

Contour cut from the top of the material

outside the line. Depth of cut 18mm

Sketch layer:

STOCK-2440_1220_18.000MM

Direction: N/A

This layer is the stock material (sheet of

plywood in this case) that you will be
cutting into. All parts are nested within this
body.

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Sketch layer:

FRONTIER-DESIGN-LOGO

Direction: N/A

Just serves as branding for our files. Can

be deleted to ‘tidy up’ the drawing

Sketch layer:

TOLERANCE_00.00

Direction: N/A

All our files are supplied with 0 tolerance

Zero tolerance joints
on joints. There are multiple ways to offset
material thickness, therefore we leave it at
the discretion of manufacturers to apply
with their own ‘best practise’

Note: For additional information about preparing files for milling check out our blog, YouTube page or
forum. You also have access to a team member to answer any questions you may have regarding files

6
Materials

FSC Certified Birch plywood*

Grade: B/BB

Size: Length; 2440 Width; 1220

Thickness: 12mm

FSC Certified Birch plywood*

Grade: B/BB

Size: Length; 2440 Width; 1220

Thickness: 18mm

Note: If possible plywood should be FSC certified. FSC certification ensures that
products come from responsibly managed forests that provide environmental, social
and economic benefits.

7
Finishing/Assembly List of the standard products to be used for
finishing /assembly. Contact us if you can’t
Materials
 source something from this list

Sandpaper Osmo Polyx raw (3044)

Grits: p120, p240, p400 Hard wax oil

Lint free cloth PVA Wood glue

For oil application Ideally non staining, quick drying

Hex key 4mm Castor with/without brake

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Length: varies Height:70mm Wheel Diam: 50mm

Hardware/fasteners List of the standard products to be used for

finishing /assembly. Contact us if you can’t
Materials source something from this list

Confirmat screw Insert nut

Thread size M6
Ø Diameter: 7mm Length: 10-13mm
Length: 50mm

Wooden Dowel Furniture bolt

Ø Diameter: 8mm Thread size M6
Length: 25mm,30mm Length: 30, 40, 50mm

Hex key 4mm 9

Router bits List of standard router bits required for
Frontier Design furniture fabrication
Materials

Compression bit

Ø Diameter: 6.35mm

Down cut bit

Ø Diameter: 6.35mm

Up cut bit

Ø Diameter: 6.35mm

10
Router bits cont. List of standard router bits required for
Frontier Design furniture fabrication
Materials 


Chamfer bit

Ø Diameter: N/A

Angle: 45 degrees

Spoil-board
surfacing/ Rabbeting

Ø Diameter: Varies

Note: Due to differences the huge variations between machine, tool brand and
personal manufacturing preferences feeds and speeds are not supplied. Please refer
to information supplied by tool/CNC manufacturer

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Frontier System Non flat pack



The Frontier Design System is a collection of interchangeable, stackable modules able to

change and adapt to its users requirements. This is an alternate route to flat-pack
furniture. This particular series of furniture should be supplied ‘ready-for-use’.

Manufacturer Hardware

A list of parts/hardware required to assemble this particular system/

product. This list does not include basic workshop equipment. (See
General workshop section.) Please contact us if you are unable to source
anything from this list

! This product should be glued, clamped and supplied fully

assembled and ready for use.

Customer Hardware

A list of parts/hardware required to be provided to the customer by the Outpost

manufacturer.

No hardware to be provided

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Multi Plus System +
 Flat pack

A wall mounted storage system with endless possibilities. You can combine the Multi
Plus system in any way you like.

With multiple wall mount sizes and a range of shelfs you can go big or start small.

Can be used in almost any situation and in any room.

Manufacturer Hardware
A list of parts/hardware required to assemble this particular system/
product. This list does not include basic workshop equipment. (See
General workshop section.) Please contact us if you are unable to source
anything from this list

! All shelves should be pre-drilled ready for customer assembly.

We recommend using a ⌀6-6.5mm wood drill bit.

All shelf sides should be countersunk using a countersink drill bit

in order to make the assembled screws flush.

Contact us for recommendations.

Customer Hardware/Documents
A list of parts/hardware required to be provided to the customer by the Outpost
manufacturer.

Included documents: ‘ProductName’_Outpost_Customer_Assembly_Guideline.pdf

Depending on type of product* you will/may be required to provide the following:

x 1 per order

Wooden dowel

4mm Hex key

⌀8mm x 25-30mm Confirmat screw (hex head)

For customer assembly ⌀7mm x 50mm

*For hardware relating to each specific product refer to the products ‘assembly guideline’ This is a
general overview

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Furniture (Other) Flat pack

Kompis desk

Whether you work from home or in the office, this is your new best friend. A neat single
person work station. Plenty of storage underneath and a handy charging hole. A
generous built in cable storage compartment allows you to keep cables and clutter off
your work area, leaving a lovely surface to work on and be creative.
 

Manufacturer Hardware
A list of parts/hardware required to assemble this particular system/
product. This list does not include basic workshop equipment. (See
General workshop section.) Please contact us if you are unable to
source anything from this list

x 36 x8 ! Product should be fully

assembled and checked for
balance etc. prior to shipping.

Wooden dowel
M6 Insert nut
Furniture bolts and legs can be
⌀8mm x 25-30mm 10-13mm removed for shipping

Customer Hardware
A list of parts/hardware required to be provided to the customer by the Outpost
manufacturer.

x4 x4

M6 furniture bolt
M6 furniture bolt

30mm 50mm

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Furniture (Other) Flat pack

Gullig stool

A chunky yet agile stool with simple features and minimal design. With its large sitting
surface it’s a perfect place to sit and work or just generally be creative. Combine with the
KOMPIS Desk to get the complete workspace. 
 

Manufacturer Hardware
A list of parts/hardware required to assemble this particular system/
product. This list does not include basic workshop equipment. (See
General workshop section.) Please contact us if you are unable to
source anything from this list.

!
Product should be fully
x 20 x4 assembled and checked for
balance etc. prior to shipping.

Wooden dowel
M6 Insert nut
Furniture bolts and legs can be
⌀8mm x 25-30mm 10-13mm removed for shipping

Customer Hardware

A list of parts/hardware required to be provided to the customer by the Outpost

manufacturer.

x4

M6 furniture bolt

30mm

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Furniture (Other) Non flat pack

Lagom chair

A modern chair in all aspects. Simple, compact and playful. Perfectly proportioned this
chair is the essence of what we wish to achieve at Frontier Design. Clean and simple
design, made from great materials. And within reach of everyone. 

Manufacturer Hardware
A list of parts/hardware required to assemble this particular system/
product. This list does not include basic workshop equipment. (See
General workshop section.) Please contact us if you are unable to
source anything from this list

x8 x8
! This product should be supplied
full assembled and ready for use.

Wooden dowel
M6 Insert nut

⌀8mm x 25-30mm 10-13mm

Customer Hardware

A list of parts/hardware required to be provided to the customer by the Outpost

manufacturer.

x8

M6 furniture bolt

30mm

16
Furniture (Other) Flat pack

Enkelt table

Perfect for large gatherings or cosy meetings. This table is perfect for most situations. It
has a sturdy look but with clean and slim lines blends into most interiors. Ideal at home, in
the office or any creative space. Easily assembly and disassembly with outward facing
bolts that gives an extra flourish and modern touch. 

Manufacturer Hardware
A list of parts/hardware required to assemble this particular system/
product. This list does not include basic workshop equipment. (See
General workshop section.) Please contact us if you are unable to
source anything from this list

!
Product should be fully
x 16 assembled and checked for
balance etc. prior to shipping.

M6 Insert nut
Furniture bolts and legs can be
10-13mm removed for shipping.

Customer Hardware

A list of parts/hardware required to be provided to the customer by the Outpost

manufacturer.

x 16

M6 furniture bolt

30mm

17
Furniture (Other) Flat pack

Enkelt bench

An ideal place to sit. Whether it be at home with family or a casual meeting space, Enkelt
Bench is at home anywhere. It has a sturdy look but with clean and slim lines blends into
most interiors. Ideal at home, in the office or any creative space. Easily assembly and
disassembly with outward facing bolts that gives an extra flourish and modern touch.  

Manufacturer Hardware
A list of parts/hardware required to assemble this particular system/
product. This list does not include basic workshop equipment. (See
General workshop section.) Please contact us if you are unable to
source anything from this list

x 16
!
Product should be fully
assembled and checked for
balance etc. prior to shipping.

M6 Insert nut
Furniture bolts and legs can be
10-13mm removed for shipping.

Customer Hardware

A list of parts/hardware required to be provided to the customer by the Outpost

manufacturer.

x 16

M6 furniture bolt

30mm

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Finishing Products
All product should be finished to a high standard. All parts should be oiled and
smooth. Any parts that should be glued together should not be sanded or oiled. For
example joints and parts that are to be combined with glue and dowels.

A B

Dowels inserted and parts glued before For optimal strength joints should not be
finishing. Be careful when joining parts with sanded or oiled. Except parts that customers
dowels so that they don’t break through the will interact with or parts that will not be glued.
material surface. eg. Multi Plus should be sanded and oiled.

Sand with 120 grit All parts and edges

Unfinished Product excluding A or B (see above)

!
Sand with 240 grit. All parts and edges
excluding A or B (see above)

Do not over-sand surfaces, edges or corners

Oil all parts and edges excluding A or B (see
above). Wait recommended drying time.

Lightly sand with 400 grit. All parts and edges

excluding A or B (see above)

Oil all parts and edges excluding A or B (see

above). Wait recommended drying time.

Sand with 400 grit all parts and edges

Finished Product excluding A or B (see above). Wipe all parts
ready for customer with a damp cloth. Product ready for
inspection. All surfaces should be smooth and
free from oil residue.
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General Workshop


No two workshops are the same. Our philosophy is not to interfere with your own
particular process…as long as the outcome is similar. Here is a basic list of tools
that are ideal for manufacturing Frontier design products.

Our workshop checklist (in no order of importance):

- CNC Machine!
- Circular saw
- Random orbital sander
- Rubber mallet
- Claw hammer
- Spirit level
- Wood glue (non staining, quick drying)
- Clamps; Quick release, F-clamp, bar clamp…etc
- Chisel
- Calliper (digital)
- Utility Knife
- Screwdriver (Multiple types)
- Handsaw
- Power drill
- Drill Press
- Drill bits (including countersink bit)

Notes:

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The Future Of Making

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