Open Systems Lab – Version 1.

0​2019

WikiHouse 
Manufacturing 
Guide 
 
A general guide to CNC manufacturing 
of WikiHouse components 
 
This is an open document, if you can add-to or 
improve it, please let us know or use the 
‘suggestions / comments’ tools. This document is 
also available in: 
Deutsch 
 

 
 Open Systems Lab – Version 1.0​2019

 
Contents 
 
1. Machines and setup 
2. Materials  
3. Workflow 
4. Tolerance 
5. Cutting heads and speeds 
6. Waste 
 
 
 
 
1. Machines, tools and setup 
 
Generally speaking, WikiHouse components 
can be cut on any CNC router that is capable 
of cutting 1220x2440mm sheets of plywood 
or OSB. These start in price and 
performance from a Marchant Dice or 
ShopBot through to more expensive 
industrial-grade CNC machines.  
 
However, to operate at a reasonable speed, 
precision and safety, it is recommended that 
you have the best machine possible, and as 
a minimum a vacuum bed, a compression 
cutting head and, of course, a good 
dust-extraction system. In an ideal world, of 
course, an industrial-grade CNC machine 
with auto-feeding capability will dramatically 
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increase production speed. Although if you 

cannot afford such a huge step-up in 
machinery, it is also possible to scale 
incrementally by running two or more 
machines side-by-side. 
 
Although you should always carry out your 
own full health and safety risk assessment, 
as a minimum operators should wear full 
Personal Protective Equipment (PPE), 
including eye protection, ear protection, dust 
masks and gloves. 
 
Your facility will require a reasonable level of 
vehicle access (ideally suitable for vans and 
lorries) – at a minimum a doorway capable of 
delivering a pallet of material in. As well as 
the machining area, you will also require a 
storage area for materials, offcuts and 
manufactured parts awaiting shipping. We 
recommend this area should be at least 
50m​ . If you are also putting together 
2​

sub-assemblies as they come off the 

machine, you will need an assembly area to 
do this with a flat, solid, long workbench area 
or floor. 
 
Ensure that materials and partis are kept dry, 
out of direct sunlight and away from direct 
sources of heat (such as radiators or hot 
pipes), as this may cause the plywood to 
expand, shrink or warp. 
 
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For shipping of parts you may also wish to 
purchase a polypropylene strapping machine 
for packaging, and cardboard boxes for 
small parts such as pegs. 
 
 
 
 
2. Materials 
 
At present all WikiHouse products are 
manufactured using 2440mm x 1220mm x 
18mm structural timber. In principle this can 
be any form of structurally certified panel 
product that a structural engineer is willing to 
specify, but usually it will be spruce plywood 
or structural OSB. 
 
Occasionally WikiHouse solutions may use 
some 6mm or 12mm sheets also, these can 
be treated in the same way. 
 
The single most challenging factor in these 
materials is the fact that their size and 
thickness will vary slightly from the stated 
thickness of 18mm. This may be due to 
moisture expansion, or simply manufacturing 
variance. 
 
This is not an insurmountable problem, but it 
requires close attention. This is why 
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tolerances are so important (see section 4 

below). 
 
 
 
3. Workflow 
 
1 Files 
WikiHouse manufacturing files arrive as a set 
of 2D profiles, nested onto 2440mm x 
1220mm sheets in CAD (.dxf or .dwg) format, 
with named layers. Generally they will only 
require one-sided cutting, and will have a 
relatively low complexity in terms of layers. 
 
In the case of large cutting jobs, this will 
likely be accompanied by a Bill of Parts (in 
the form of a live spreadsheet) to help you 
keep track of quantities and check that no 
parts are missed. If you are able to keep this 
updated as you go, it also allows the 
customer to follow task progress. However, 
you may have your own internal systems for 
this. 
 
2 Convert to g-code​These files will need to 
be converted into g-code for your machine 
using your preferred Computer Aided 
Manufacturing (CAM) software. With 
Blackbird this should take less time than ever 
before, since it will comprise fewer unique 
sheets. 
 
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3 Check materials​Check the thicknesses of 

the panels. (see Section 4) 
 
4 Test  
Even if you are not assembling the 
sub-assemblies, you should perform a test 
assembly of the first of each type of part (see 
section 4 below) to check the tolerances 
before proceeding. You should also test 
again regularly during cutting – if there is a 
problem, stop.  
 
4 Assembly-off-the-machine 
If you are assembling the sub-assemblies, 
the best way to do this is as they come off 
the machine. This works timing-wise too, as 
most sub-assemblies will take less time to 
put together than it takes to cut the next 
sheet, so this task can be performed by the 
machine operator while the CNC machine is 
running. ​More information required on 
timings.  
 
This also avoids the need to store and 
transport individual parts, risking them 
getting lost or muddled. 
 
5 Shipping​Once parts are prepared for 
shipping they should be loaded into a large 
van (if possible) or a covered lorry for 
shipping to site. As far as possible, try to 
avoid the parts getting wet at all times. 
Although a light sprinkling of rain on the way 
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out should not be a problem provided they 

are being moved to a dry, ventilated space or 
vehicle for storage. 
 
 
 
 
4. Tolerances & offsets 
 
The single most challenging factor in the 
production and assembly of the WikiHouse 
chassis is managing tolerance. For the 
purposes of manufacturing, the primary issue 
are variations in sheet thicknesses, either as 
a result of manufacturing variance or 
expansion following exposure to moisture. 
 
Offsets 
All WikiHouse files will contain standard 
offsets. 
 
Usually these will be, for example, a 0.25mm 
offset – however in some cases some 
specific edges, holes or slots may be offset 
by more than this, or less, and may contain 
‘crush joints’ (joints that are intended to be 
malleted together once only, and hold 
together).  
 
This creates tolerance for a range of sheet 
thicknesses. This is likely to be +/- 0.5mm, 
but you should always check the specific 
tolerance given in the files. 
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For example, if the sheet thickness is 18mm 
and the thickness tolerance is +/- 0.5mm, 
you should only use sheets that are between 
17.5mm and 18.5mm thick.  
 
When checking sheet thicknesses any sheets 
that are outside the 0.5mm tolerance should 
be set aside and used for the large facing 
panels of wall and roof cassettes only. 
 
 
 
Checking tolerance 
If you are not assembling the sub-assemblies 
straight away, you should test-assemble the 
first of each type of part. If the tolerances are 
too loose, or too tight, stop immediately. 
Either the tolerances will need to be adjusted 
on the files, or different sheets used in the 
cutting process. If the former, you should 
contact the chassis designer before making 
any changes before proceeding.
 
 
 
5. Cutting heads and speeds 
 
When it comes to bit-size, cutting speed and 
number of passes there is no single ‘correct’ 
combination. The key is finding the right 
balance between running the CNC too slow, 
which will burn out cutters, or too fast which 
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may leave splintered edge and risk breaking 

router bits.  
 
By default, the dogbones in WikiHouse files 
allow for any cutting bit size up to 10mm. 
Previous manufacturers have used a range of 
sizes, using 2-3 passes, typically achieving 
overall production rates of 15 to 30 minutes 
per sheet. 
 
During testing you will be able to find the size 
and speed that works best and fastest for 
your machine.  
 
If you are a CNC operator and would be 
willing to share your optimum settings for 
manufacturing WikiHouse components, 
please add them to the table below using the 
suggestions. 
 
 
Machine  Material  Bit size  Cutting  Passes  Av. 
speed  time 
per 
sheet 

           

           

           

           

           

 
 
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6. Waste 
 
Over time we are seeking to maximise sheet 
efficiency, however there are, by definition, 
leftover offcut ‘frames’ of plywood. 
Obviously, these need to be disposed of in 
the most sustainable way possible. There are 
two main options: 
 
Reuse 
If there are a significant number of identical 
offcut frames, they can be fixed together in a 
stack. Filled with soil, these could form 
planters, which could be sold in their own 
right or integrated into the landscaping 
strategy of the project. ​This has yet to be 
tried – but if you do so, please share 
instructions here. 
 
Recycling 
Offcut timber can be collected and 
reprocessed as a replacement wood fuel or 
chippings. ​If you know the name of any 
companies or councils that provide this 
service (and typical prices), please share 
them here. 
 
 
 
 
 
 Open Systems Lab – Version 1.0​2019

 
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Illustrations by ​
Open Systems Lab​2019. 
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