Make precision cuts without math.
The Thiosphere uses irregular polygons — not simple rectangles. Each panel has specific angles and dimensions. Getting these right by measurement alone requires careful work and invites errors.
Templates eliminate the problem. Trace. Cut. Done.
This post explains our template options and when to use each.
The Measurement Problem
Traditional construction uses rectangles. Measure length, measure width, cut. The angles are always 90 degrees. Simple.
The Thiosphere is different. Panels are pentagons and truncated triangles. Angles range from 60 to 108 degrees. Dimensions aren't round numbers — you're cutting pieces at 23.47 inches, not 24 inches.
This creates challenges:
Measurement errors compound: If you're off by 1/8 inch on one dimension, the panel might not fit. Multiply that across 24 panels, and the structure won't close.
Angles are hard to verify: Is that cut actually 72 degrees, or is it 71? Hard to tell by eye. A protractor helps, but setting up precise angles repeatedly is tedious.
Repetition creates fatigue: By the 20th panel, your attention wanders. That's when mistakes happen.
Templates solve all three problems. The template is already perfect. You just trace it.
Paper Templates
Price: $25
Paper templates are full-scale patterns for every panel in the Thiosphere.
What You Get
- PDF files sized for architectural plotters
- All outer shell panels (12 unique shapes)
- All inner shell panels (12 unique shapes)
- Platform components
- Door and window frames
- Registration marks for alignment
How to Use Them
1. Print at a copy shop: Take the PDF files to Staples, FedEx, or a local print shop. Ask for architectural or engineering prints. Cost is typically $3-8 per sheet.
2. Verify scale: Each template includes a 12-inch reference line. Measure it. If it's not exactly 12 inches, the print is scaled wrong — ask them to reprint at 100%.
3. Cut out the template: Use scissors or a utility knife. Precision matters less here because you're tracing, not using the paper edge as a guide.
4. Trace onto plywood: Lay the template on your plywood, align with the edge or a reference line, and trace with a pencil.
5. Cut the plywood: Follow the pencil line with your saw. The accuracy is now in your hands, but the layout is guaranteed correct.
Best For
- One-time builds: If you're building a single Thiosphere, paper templates are economical.
- Budget-conscious builders: $25 + $30 printing is much cheaper than MDF alternatives.
- Verification: Even if you plan to cut by measurement, print paper templates to verify your work.
Limitations
- Paper tears and creases easily
- Humidity can distort paper
- Tracing onto plywood requires care
- Not reusable for multiple builds
MDF Templates
Price: $75
MDF templates are rigid routing guides laser-cut from 1/4" medium-density fiberboard.
What You Get
- Complete set of MDF templates for all unique panel shapes
- Templates are precisely cut to finished panel dimensions
- Each template labeled with panel number and orientation
- Storage/carrying case for organized transport
How to Use Them
1. Rough cut the plywood: Cut your plywood slightly oversized (1/4 to 1/2 inch larger than final dimension).
2. Attach the template: Use double-sided tape or clamps to secure the MDF template to the plywood. The template represents the exact final size.
3. Flush-trim with router: Using a router with a flush-trim bit (bearing-guided bit), route around the template edge. The bearing follows the MDF; the bit cuts the plywood to match.
4. Repeat: Remove the template, attach to the next rough-cut piece, route again.
Why This Works
Flush-trim routing is a professional technique for creating identical parts. The router bit cuts exactly where the bearing rides. If the template is perfect (and laser cutting ensures it is), every part cut with that template is perfect.
The result: panels that are interchangeable. Any panel cut from Template 3 fits any position that requires Template 3.
Best For
- Multiple builds: If you're building more than one Thiosphere, MDF templates pay for themselves quickly.
- Commercial builders: Anyone planning to sell Thiospheres needs MDF templates for consistency.
- Maximum precision: Router-cut edges are more accurate than hand-traced cuts.
- Speed: Once set up, each panel takes 2-3 minutes. Measurement-based cutting takes 10-15 minutes per panel.
Limitations
- Requires router and flush-trim bit ($80-150 if you don't have them)
- More expensive upfront
- Heavier to ship
- Requires rough-cutting first
Comparison
| Factor | Paper Templates | MDF Templates |
|--------|-----------------|---------------|
| Price | $25 + ~$30 printing | $75 |
| Precision | Good (trace-dependent) | Excellent (router-perfect) |
| Reusability | One-time use | Unlimited |
| Required tools | Scissors, pencil | Router, flush-trim bit |
| Speed per panel | 10-15 minutes | 2-3 minutes |
| Best for | Single build, tight budget | Multiple builds, production |
When to Use Each
Choose paper templates if:
- This is your first and only build
- Budget is the primary constraint
- You don't own or want to buy a router
- You want to verify measurements before cutting
Choose MDF templates if:
- You're building multiple structures
- You plan to build for others (commercial)
- You own a router or plan to buy one
- Precision and speed matter more than upfront cost
Get both if:
- You want to verify with paper before committing to MDF cuts
- You're building one now but might build more later (paper now, MDF later)
- You're teaching others to build (paper for learning, MDF for production)
Technical Details
Paper Templates
- PDF format, vector-based (scales without pixelation)
- Designed for ANSI E or Arch E size paper (36" x 48")
- Some panels require multiple sheets with alignment marks
- Includes 1" margins for print trimming
MDF Templates
- 1/4" MDF, laser-cut
- Templates are undercut by 1/16" to account for flush-trim bit diameter
- Labeled with etch marks (won't wear off)
- Holes for clamping or hanging storage
- Ships flat, packaging designed to prevent warping
The Economics
Let's do the math for different scenarios:
Scenario 1: Single Build, Paper Templates
- Paper templates: $25
- Printing costs: $30
- Total: $55
Time per panel: ~12 minutes
Total time for 24 panels: ~5 hours
Scenario 2: Single Build, MDF Templates
- MDF templates: $75
- Router (if needed): $100
- Flush-trim bit (if needed): $25
- Total: $75-200
Time per panel: ~3 minutes
Total time for 24 panels: ~1.5 hours
Scenario 3: Two Builds, MDF Templates
- MDF templates: $75 (reused)
- Router + bit: $125 (one-time)
- Per-build template cost: $37.50 amortized
Scenario 4: Five Builds, MDF Templates
- Per-build template cost: $15 amortized
MDF templates become cheaper per-build than paper after the second use.
Community Template Sharing
One pattern we've seen: local builder groups sharing MDF templates.
If five builders in an area each want to build one Thiosphere, they don't need five template sets. They can:
- Buy one MDF set collectively ($15 each)
- Schedule builds sequentially
- Pass templates between builders
This is totally within the open-source spirit. We encourage it.
The Discord has a #template-sharing channel where builders coordinate local sharing.
Ordering
Both template options are available in the store.
Paper Templates ($25): Immediate download. Print yourself at any copy shop.
MDF Templates ($75): Ships within 5-7 business days. Includes all templates + storage case.
Both: Paper included free with MDF purchase. Use paper to plan, MDF to build.
The Invitation
Measuring is hard. Tracing is easy.
Whether you choose paper or MDF, templates eliminate the most error-prone part of the build. The thinking is already done. You just execute.
Precision without math. That's the goal.
Get Paper Templates — $25, immediate download.
Get MDF Templates — $75, shipped to you.
Join the community — Find local builders to share templates.