Forgedeck is a modern desk shelf, inspired by desk shelves from brands such as Grovemade and Balolo. It is based on IKEA shelves and comes in a variety of colors, including white, walnut, black, and beige. It includes trays in two sizes, lined with cork, which adds a premium feel.

You can choose to install or not install metal shelves to make a Forgedeck. The pictures show the scene of installing metal shelves and one shelf for each tray.

Materials list

To make a Forgedeck, you need:

1. IKEA Bergshult shelf, in any color.IKEA Bergshult
2. It requires about 500 grams of consumables. The Bambu PETG HF black filament works very well, but you can also use PLA for printing.
3. Six
4. (Optional) Corkboard with adhesive, used for lining trays.
5. (Optional) Metal shelves, made of 3mm aluminum, are cut, bent, and anodized to achieve the best surface effect.

Printed parts

Base

If you choose to use metal shelves, you will need two "shelf base" components and one "shelf without base" component.

Otherwise, if you don't want a metal shelf, please print two or three "base without shelf" parts. If you don't plan to place heavy items in the middle of the shelf, use two; if you need additional strength, use three.

• Any material, but I recommend PLA or PETG
• Floor height of 0.2mm
• 2-3 layers of walls
• At least 15% filling
• Support: Ordinary
• Fuzzy skin settings: outline, 0.4mm dot spacing, and 0.2mm thickness.
  • If you don't use my configuration file, make sure to add a modifier to the base of the aluminum shelf groove and turn off the blurry skin in that area—otherwise, the shelf might not fit into the groove.

Calibration fixture

The calibration fixture will help us create holes for the two edge bases on the shelf, ensuring that they are the same distance from the edge. It's an auxiliary tool, so it doesn't need to be of high quality.

• Any material
• Floor height of 0.28mm
• 2-3 layers of walls
• 10% filler
• No support is needed

Tray

• Any material
• Floor height of 0.2mm
• A three-story wall
• 15% filler
• No support is needed

Assemble

A Forgedeck with metal shelves

1. Print the base. If you want a metal shelf, you need 2 bases with shelves and 1 base without shelves. If you don't choose a metal shelf, please print 2 or 3 bases without shelves.
2. Place the BERGSHULT shelf so that its bottom is facing upwards.
3. Place the calibration jig at the bottom of the shelf and drill two guide holes with a small drill. This is not necessary, but it will help the shelf be easily installed with screws.
4. Place the two edge bases on the bottom of the shelf, with the larger holes facing upwards. Make sure the edge base with the shelf groove rotates so that the groove is facing inwards.
5. Use a screwdriver to insert the countersunk wood screw into the hole in the base, and then screw it into the shelf.
6. Place the metal shelf into the installed grooved edge base. Please note that the curved part of the metal shelf should face towards the back.
7. Place another shelf base in the metal shelf and position it so that the shelf is aligned and stable. This will be the middle base.
8. Mark the holes in the middle base and optionally drill the guide holes. Then, use wood screws to fix the base in place.

Tray

1. Printing tray.
2. Use a cutting machine
   1. If your machine doesn't have a cork setting, I've found that using the denim setting with a rotating blade works very well.
3. Use adhesive tape to attach the cork lining to the inside of the tray.
4. Stick the cork rail on both sides of the bottom of the tray.