The driving factors behind the design and method of making this dodecahedron were scalability and concern over warping. In order to create a dodecahedron on a larger scale, we decided to join the sides together with machined aluminum jigs to hold them in the correct orientation for tacking. This fixture method was successful at minimizing the effects of warping and reducing the headache of manipulating larger panels.

Due to the non-standard geometry of a dodecahedron, it is difficult to make a jig using a standard three-axis mill or lathe setup. Using a four-axis lathe with live tooling, each jugget could be fully machined in one setup. This lathe was also equipped with a part catcher and bar feeder, so after the setup was completed all 60 nuggets were machined continuously with minimal interruption. The program was interrupted to replace a 1/4-20 form tap broke after 50 nuggets.

The panels were designed in Solidworks and the fit tested by 3D printing the design before they were ordered. After confirming the correct dimensions, the panels were ordered and laser cut from OSHcut.com. They are .09" 1008 high-carbon steel, because at this gauge it is resistant to warping. The design includes notches at specific intervals in order to make it easier to line up the panels and tack them together.

The dodecahedron was easy to assemble using the jigs with short screws, a drill with a driver bit, and lots of washers. Before welding the panels together, we used the jigs to assemble a test piece from similar material to try out the settings on the TIG welder. Once confirmed, we tacked all but one panel together at the notches and then removed the jigs. The last panel was attached very carefully, using filler rod to support the plate while it was tacked in place. Once all the panels were tacked, we welded up all of the seams and filled the holes. One hole remains on the bottom of the dodecahedron to prevent any warping as it cooled, and to mount on the machined stand.