Overview
Problem
How do you design a furniture piece that can be flat-packed into a cardboard box and assembled enjoyably by the receiver?
Outcome
By designing a furniture piece inspired by the childhood act of stacking wooden blocks, I evoke a sense of childhood wonder and fun.
Info
Tools
Rhino3D
AutoCAD
CNC Router
Bandsaw
Drill Press
Woodworking Tools
Timeline
3 months
Studio Instructor
Johnathon Anderson
Process
Step 1: Ideating
I brainstormed ideas and looked for inspiration while sketching possible concepts. I settled on the idea of stacking pieces to create a whole.
I then created small hand-sized prototype models out of found cardboard and toothpicks.
Sketches
Miniture model
Step 2: Modeling
I then modelled the design in CAD (computer-aided design) using precise measurements. While I modelled, I rendered how it would look and made changes.
Step 3: Drafting
I then drafted all the pieces of wood I needed to cut using AutoCAD into construction drawings. There were precise measurements to cut and angles to drill.
Each piece of wood is uniquely dimensioned with different lengths and angles of holes drilled into its corners.
This was one of the most difficult parts, as the angled dowel joinery I designed was conceptually simple but technically hard to construct.
To the right are some of the diagrams I created to remind myself how the assembly would take place. The first is a top view, and the second is a side view.
Step 4: Woodworking
I cut each piece of rectangular wood with a saw in the woodshop. Then I drilled the angled dowel connection holes into wood pieces using a custom woodworking jig.
Setup for drilling holes.
Closeup of drilled hole.
After I sanded all pieces and finished them with multiple layers of the semi-glass acrylic polyurethane finish. This end product literally contains my blood, sweat and tears (I cut my finger at some point, lol); it was also the first furniture piece I ever made.
Step 5: Assembling
Diagram of the assembly steps
Done!
And yes! I still have it as my coffee table. Five years and counting, and still super sturdy! Though I've changed the glass top to one with more rounded corners - safer corners.
