As part of my BIOE 555 assignment, I embarked on an exciting project to build a storage crate, honing my woodworking skills while applying the concepts we learned in class. As a group, we started by gathering all the necessary materials and tools. As per suggested, we chose planks of 1×4 lumber for the sides and bottom of the crate and 2×2 lumber for the corner supports, all of which was given to us in the form of pre-cut wood. We made sure we had screws, a drill, a router, and sandpaper of varying grits. 

Using the corner clamping method we learned in class, we carefully aligned the edges of the planks to form the sides of the box, and drilled pilot holes and countersunk the screws to ensure a flush finish. Once the sides were secure, we attached the bottom slats, ensuring that they fit snugly. 

Routing the edges was a key part of achieving a finish that felt as professional as possible. We used the router to create smooth, rounded edges, which not only enhanced the aesthetics but also made handling safer. For sanding, we decided to use three levels of sandpaper: 60, 120, and 240 grit. Starting with the coarsest, we sanded down rough edges and joints, progressively moving to finer grits for a smooth finish. What I feel was key here was that we actually also sanded really thoroughly the edges. I began struggling a bit with this because my hands are quite small and I got scared, but eventually, by following my group’s example, I came to feel confident while carrying out the task.

Of course, after sanding, the table was a mess and we were all tired. So we decided to take a break and return some other day. Before leaving, though, we cleaned up our station and made sure everything was in pristine condition.

Then, to maintain symmetry, we meticulously measured and marked where to place each screw, following the design we discussed in class. This careful planning ensured that the crate not only looked good but was also structurally sound.

For the handles, I utilized a jigsaw to cut out shapes from the 1×4 lumber. I basically drew the outline of the shape I desired, and cut really thin wooden “teeth” that went up to the pencil line, so that they could be later popped off. Afterward, I carefully sanded the edges to even out and smooth any rough spots, ensuring they were comfortable to grip.

Finally, we had everything done and the only missing step was attaching all the components. We carefully did this and then performed a final round of sanding to eliminate any imperfections. To give the crate a nice finish, we decided to apply a wood wax that enriched the color, protected the surface and had a smooth feeling to it.

Finally, we got our end product: Our own crate. We proceeded to use wood glue to attach our name plates (that we did during the Laser Cutting Training), turned the crate on its side to apply pressure over the glued parts, put our materials inside (including our own aprons), and cleaned everything up. The assignment was done.

This assignment not only taught me valuable woodworking skills but also provided a practical application of the theoretical knowledge from class. Building this crate really was a rewarding experience that emphasized the importance of patience, precision, and creativity in prototyping and fabrication. I most;y enjoyed the team aspect of it; we got to discuss ideas and motivate each other in times of struggle. I look forward to applying these skills in future projects!

Cost Analysis

Cost Type	Cost	Price	Source	Quantity	Total
Materials	1×4 Board	$298 per 8 feet	Lowe’s	16’’ x 9 12’’ x 6  Total: 18ft	$6.705
	Screws	$7.99 (200-piece wood screw set)	IKEA	48	$1.9176
	Sand Paper	$598 per 5 60 coarse sheets $1098 per 25 120 medium sheets $1298 per 25 2e0 very fine sheets	The Home Depot – 60 coarse – 120 medium – 220 very fine	2 x 60 2 x 120 2 x 220	$2.392 + $0.8736 + $1.0384 = $4.304
	Wood Wax	$998 per 16 oz package	The Home Depot	1/16th of the package	$0.62375
Labor	Woodworking Operator	$35 – 40/hr	Rockler  The Wood Whisperer MEI Rigging & Crating	2 hrs	$80
	Prototyping Engineer (You!)	$15/hr	–	6 hrs	$90
Design	Engineering and Development	$107K/year ~ $36.65/hr	Glassdoor	0.5 hrs	$27.48
	Iterations			0.25 hrs
Misc.	Waste and Scrap	$298 per 8 feet of wood	Lowe’s	2 feet	$0.745
Overhead	Facility Cost (Machine Time) + Quality Costs	15% of the total materials and labor costs	MEI Rigging & Crating	–	0.15 x $131.1516 = $19.67274
Total	$151.44809
Total without considering labor	$33.96809
Value of the item online	$19.99 (IKEA)

 

The cost comparison between buying a crate online and building one ourselves shows that purchasing a crate online for $19.99 is less expensive than the total calculated cost of $151.45 for building it. However, most of this total stems from the hypothetical $90 in labor costs for our own work and the $27.48 for design, while the $80 woodworking operator is included purely for comparison.

If we exclude our labor cost, which makes sense given that a key advantage of building the crate ourselves is that we don’t have to hire someone, the total cost of materials and overhead is $33.97. While slightly higher than the retail price, this difference is marginal. Additionally, the process of building the crate ourselves offers the benefit of learning new skills, which can be reused in future projects, making it a valuable investment in personal development rather than a simple financial transaction.