Modeling in Flexible Solid Hardwood

September 6, 2008
Photo Credit: Chris Mroz
Project Site: Fluted Beams LLC, Gig Harbor, WA.

3D Free form modeling in solid hardwood is possible through the use of Flexible Compressed Hardwoods.
Solid Hardwoods are engineered using a patented process that makes them extremely pliable. Prototypes,
models and molds may be fabricated in a sculptural, free form approach to work out design ideas and
concepts. The model could be digitized to generate a CAD model. Alternately, if a CAD model is already
available to create a precise mold, the part can be modeled as the mold, or on a mold and then CNC cut to
tight tolerances.
Compressed Hardwoods will both bend and twist. They can be bent to small radii in any plane, without
steam or the backing straps that steamed hardwoods require. Working with Compressed Hardwoods is
trademarked as Compression Bending or Extreme Wood Bending in the USA. The flexible wood is
pliable for long periods of time while moist (months to years), then it is fixed permanently in its shape
after bending by drying it.
An Extreme Wood Bending modeling technique is demonstrated in solid Red Oak in the photos below.
The part modeled is a prototype quarter panel for a concept supercar, which was inspired by the shape of
the Bugatti Veyron.
Figure 1: Autoclaving Clear, green hardwood that has been pre-dried to 25% Moisture Content and
dimensioned to fit the compression chamber is autoclaved (saturated steam, heat and pressure) for up to 24
hours to plasticize it.

Figure 2: Compression Using a patented process and press, the heated and softened hardwood is
compressed in length by up to 25%. Usually, 10 foot planks are compressed to 8 feet. The cell walls slide
into one another and fold up to create a sort of bellows effect. You can compare the compressed wood to
being similar to the bellows of a hospital straw. Whereas the hospital straw is very flexible, a straight
walled straw is stiff and resists bending. However, with Compressed Hardwoods, there is no visible
change in the appearance. Compressed Hardwoods maintain their flexibility for months to years as long as
they are kept moist. The wood is fixed in its shape after bending by drying it.

Figure 3: Rope Knot Cold Bending By Hand. Compressed Hardwoods are so flexible, that they can be
tied in a knot like a piece of rope. This series of photographs shows a long strip of White Ash, 1 x
being bent into a complex curve. Note that Compressed Hardwoods are capable of bending in any plane,
and twist as well. Once bent in one direction, it can be re-bent in another direction if desired. No backing
straps are required because Compressed Hardwoods can stretch, unlike steam bent wood. Also, no heat, or
steam is required by the wood bender. The wood may be permanently fixed in its new shape by drying it.

Figure 4: Free form modeling on the bench A prototype is being laid up from strips of solid Red Oak
(dimensions = 1 1/8 x 1 1/8 x 100). Screws and clamps are used to keep the strips in tight alignment.
Once screwed, the clamps are removed so that the next layer can be applied. Oak strips are stepped
where a steep cross grain slope is required. (In photo: Taran Gomulkiewicz)

Figure 5: Compressed Hardwoods are flexible as long as they are moist. After bending, they are dried in a
kiln or drying oven to fix the shape permanently. Image shows views of bent parts in a small kiln
fabricated from foil backed rigid foam panels, a fan, and a heat source.

Figure 6: After drying, the model is taken apart and reassembled with glue. We call this the Whale Bone
stage.

Figure 7: Grinding out the shape from the rough mock-up. (In Photo: Chris Mroz)

Figure 8: Filing the surface to prep for final sanding. (In Photo: Chris Mroz)

Figure 9: Final Sanding Operations. (In photo, Chris Mroz)

Figure 10: Final model. Solid Red Oak, finished with Tung Oil, but could be primed and painted. Size is
18 x 24 x 64. Weight is 22 lbs. (In Photo Mroz)