Toy Train

This is a project I made for the IGCSE Resistant Materials class. The toy train was designed for my 7-year-old cousin. It has a few games and storage features as well.

Tools:

• CNC (for cutting the plywood and MDF)
• Laser cutter (for cutting the acrylic and plywood)
• Glasspaper + metal files
• Vice
• Drill
• Mallet

Materials List:

• 10mm plywood
• 6mm plywood
• 8mm colored MDF
• 6mm acrylic

Using the Fusion 360 CAD, I designed the 3 carts of the train, ensuring the pieces' thickness matched the thickness of the plywood and MDF available.

A CNC was used to cut out the plywood and MDF (using multiple passes).

A laser cutter was used to cut out the acrylic. The acrylic can be replaced with other materials, e.g nylon (hard to cut through), plywood, MDF, etc.

The first cart has a curved roof, which can be made by laminating thin pieces of wood veneer, essentially making your own curved plywood.

A laser cutter to cut acrylic (for wheels) and 3mm wood sheets (for the loops and hooks used to attach the carts to each other).

A coping saw to cut dowels for the wheels.

A center punch and eclectic drill to cut the holes.

Sand down each piece of wood individually. This takes a really long time :P.

I used sandpaper + a cork sanding block, an electric sander (only large flat pieces), and metal files (small details).

If there are imperfections (holes, dents, cracks) in the wood, you can mix excess wood dust with wood glue to make a wood filler. I filled the cracks, then waited for them to dry, then sanded down the bumpy surface.

I used non-toxic wood varnish for colored parts (adds vibrancy) and wax for the original plywood color (brings out the wood grain). I then used a mallet to hit all the pieces into place (wear ear guards).