ExLAB | Timber Workshop Design Journal | Justeen (Hsin Te) Tsai

ExLaB Justeen Tsai 784180

exlab.org

Design Journal 04/01/2021

Timber Furniture Workshop (1)

ExLaB Contents 1.0 Introduction 2.0 Stool Exercise 01 3.0 Precedent Study 4.0 Experiment for Major Project 5.0 Major Project Design vision 6.0 Major Project Preparation 7.0. Reflection Part I 8.0 Final Design - Float 9.0 Final Reflection

Table of contents

Timber Furniture Workshop (2) 3 4 18 28 46 58 65 67 96

ExLaB

Timber Furniture Workshop (3)

1.0 Introduction

The Experimental Design Lab is an investigation into material and process driven design. It suggests an alternative, “bottom-up” approach to the conceptual process where playful experimentation with materials and hacking of both traditional craft methodologies and contemporary digital fabrication equipment leads ultimately to the design of a functional item of furniture. Risk is encouraged, and hard-earned failure is rewarded in parallel to successes.

Physical experimentation lies at the core of the ExLaB pedagogy. Designers are encouraged to get out of sketchbooks and get their hands dirty.

The process becomes as important as the final outcome and provides a glimpse of the breakthroughs, the heartbreaks, the red herrings and the intense amount of labor that goes into the ExLaB process

(1) Final Furniture Design - Float

ExLaB 2.0 Stool Exercise 01

Timber Furniture Workshop (4)

(1) AJ - 01, Arthur Wibisono & Justeen Tsai, 2021

Stool Exercise 01

AJ - 01

ExLaB

Timber Furniture Workshop (5)

(1)

(2)

(3)

(4)

(1) Timber selection and preparation, (2) Moisture Content - through soaking, (3) Creating a mould, (4) Steaming timber.

2.1 Steam Bending Preperation

AJ - 01

ExLaB

(1)

Timber Furniture Workshop (6)

(2)

(3) (4-11) Most left to Right 1. Tasmanian Oak 10 mm - soaked for 2 days, steamed for 2 hours 2. Tasmanian Oak 5mm - soaked for 2 days, steamed for 2 hours - Free hand bend 3. Experimental bent 4. American Oak 10 mm - soaked for 2 days, steamed for 2 hours 5. American Oak 10mm - soaked for 2 days, steamed for 2 hours 6-7. American Oak 8mm - soaked for 2 days, steamed for 2 hours without compression tape 8-11. American Oak 8mm - soaked for 2 days, steamed for 2 hours with compression tape

(1) Initial design concept - Tasmanian Oak 5mm, soaked for 1 day, steamed for 2 hours slotted through (2) Second Iteration - Tasmanian Oak 5mm, soaked for 1 day, steamed for 2 hours - free formed (3) Tasmanian Oak 10mm - soaked for 2 days and steamed for 2 hours.

2.2 Steam Bending Testing

AJ - 01

ExLaB

(1)

Timber Furniture Workshop (7)

(2)

(1) Tasmanian Oak 5mm - soaked for 2 days, steamed for 2 hours, free hand (2) Clamping process - as the wood bent according movement.

2.3 Steam Bending Process - Free Forming

AJ - 01

ExLaB

(1)

Timber Furniture Workshop (8)

(2)

(3)

(4)

(5)

(7)

(6)

(1) Preparing the mould (2) Jig 01 - Clamped after bending (3) 10mm American Oak - does not bend well enough, fractured proving it difficult to bent the timber in one continuous motion(4) Making the compression strap with punched metal strapping from Bunnings (5) 6mm American Oak - created a smooth bend in one single motion (6) After leaving it to air on the jig for 1 hour, moved to the drying rack (7) final timber strips taken off the drying rack.

2.4 Steam Bending Process

AJ - 01

ExLaB

(1)

(5)

Timber Furniture Workshop (9)

(2)

(3)

(6)

(4)

(7)

(1) Initial half lap joint design (2) Initial look based on half lap joinery system (3) Curved timber strips does not fall flat on the ground (4) Using the disk sander to angle the curved strips (5) Flattened curved timber strips to align with the ground (6) Chamfering the edges of the half lap with router table for a seamless finish (7) Outcome of the chamfering from the router table - creating a more finesse look.

2.5 Connection and Details

AJ - 01

ExLaB

Timber Furniture Workshop (10)

Joining the curves together proves to be the greatest challenge. We did not anticipate on what connection to use.

As we decided to keep the stool as simple as possible

(1)

(2)

to highlight the bending motion, we opted for a half lap joinery system. However, we did different detailing approach to a conventional half lap. Each exposure is chamfered to have a tapered look. In the sides where the curves is the most visible, we tapered even further to accentuate the curves while keeping the joinery as indistinguishable as possible.

(3) (1) Chamfering the inner cuts of half lap to create uniformity and accentuate the effect of the half lap joinery (2) Outcome of cutting the chamfer through table saw - creating a chocolate bar pattern (3)Comparison between two methods - most left, through router table that creates a smaller cut and a burn on the end grain. Center, without inner chamfer. Most Right, inner chamfer through table saw that provides bigger cut and a more uniform cut with less burn.

2.5 Connection and Details

AJ - 01

ExLaB

Timber Furniture Workshop (11)

(1)

(2)

(3)

(1) Split ends created by the bending motion (2) Applying glue to the split ends, taping it and clamping it to leave overnight (3) Once the glue is dry, hand sanded for 2 rounds before using the hand-held sander for a finer finish.

2.5 Connection and Details

AJ - 01

ExLaB

Timber Furniture Workshop (12)

(1)

(4)

(2)

(3)

(5)

(6)

(7)

(8)

(1) Creating a wedge to cut the back bottom half lap - to accommodate two more bent timber strips intended as a book stand (2) Cutting the half lap on top of the wedge with table saw - creating and angled half lap (3) Rounding the edges for the book stand and the seat with belt & disk sander (4) Dry clamping the gluing process to eliminate unnecessary errors (5) First round of gluing process - clamped (6) Adding timber bits to prevent clamping marks (7) Due to the spring back after the gluing and clamping process, the bottom surface of the stool is not flat - a final round adjustment done through table saw.

2.5 Connection and Details

AJ - 01

ExLaB

(1)

Timber Furniture Workshop (13)

(2)

(3)

(4)

(1) Final round of sanding to clean glue marks (2) Final look on the connection, the chocolate bar effect (3) Applying first coat of finishing (4) We opt for a more fresh sanded look with Evolution Raw Light Stain

2.6 Finishing

AJ - 01

ExLaB

Timber Furniture Workshop (14)

Upon Oak

experimenting, timber

although

the

curves 5mm

both

5mm

can

be

does

not

and bent offer

10mm

American

successfully, strength

and

stability. We decided to pursue with the 8mm curves.

As steam bending process has multiple variables that cannot be controlled, we decided to follow what the material allowed us to do. Therefore, the form follows the material.

Our

form

is

inspired

by

one

curve

and

one

mould,

however, manipulated in different ways to create varying curves and effect. We opted not to go for a flushed finished - since every curve is unique, we decided to break it apart to further showcase the process of the steam bending and accentuate each curve. The outcome is simple yet detailed to express the motion of bending.

(1)

Final AJ -01 Stool

AJ - 01

ExLaB

Timber Furniture Workshop (15)

AJ - 01

ExLaB

Timber Furniture Workshop (16)

AJ - 01

ExLaB

Timber Furniture Workshop (17)

AJ - 01

ExLaB 3.0 Precedent Study

(1) Bending Bridge, Centro de Estudios Superiores de Diseño de Monterrey, CEDIM, 2018

Timber Furniture Workshop (18)

ExLaB

Timber Furniture Workshop (19)

(1) Bending Bridge, Centro de Estudios Superiores de Diseño de Monterrey, CEDIM, 2018

3.1 Precedent 01

ExLaB

Sping back is one of the significant issues for steam bending; in this bridge design, they layered up two steam bend piece to secure the spring back.

(1) Bending Bridge, Centro de Estudios Superiores de Diseño de Monterrey, CEDIM, 2018

Timber Furniture Workshop (20)

ExLaB

Timber Furniture Workshop (21)

Wood Chair , Marc Newson, 1988, Canadian Rock Maple and Australia Coachwood.

3.2 Precedent 02

ExLaB

Timber Furniture Workshop (22)

The Wood Chair from Marc Newson is an iconic furniture piece made with steam bending. It is intriguing how the designer space out the ununiform steam bend piece to make the strip looks uniformed, which we adopted for our stool design.

Wood Chair , Marc Newson, 1988, Canadian Rock Maple and Australia Coachwood.

ExLaB

Timber Furniture Workshop (23)

Etcetera lounge chair , Jan Ekselius, 1970

3.3 Precedent 03

ExLaB

Timber Furniture Workshop (24)

The Etcetera Lounge chair is an dimention and proportion reference for my final design.

In the fucure i would want to try to use steam bending to create this kind of curve geometry.

Etcetera lounge chair , Jan Ekselius, 1970

ExLaB

Timber Furniture Workshop (25)

Brutalisim is one of the architecture asthetic I like the most. The lounge chair is a great example of expressing architecture style into furniture design and making.

Loop Chair, Willy Guhl, 1954

3.4 Precedent 04

ExLaB

Timber Furniture Workshop (26)

From first sight I thought it is made out of timber steam bend, however after reading through the design process, the bow tie chair is actually produced from a series of 13 sections of bent, laminated bamboo. Through repetition, ‘bow tie chair’ delivers a unique combination of simplicity and a very different way of using bamboo

Bow Tie Chair , Gridesign

3.5 Precedent 05

ExLaB

Timber Furniture Workshop (27)

What intrigued me the most about the Motion chair may look like a steam bend furniture design. However, this is entirely made out of sustainably grown and harvested plywood. Where it makes me rethink the process of making curve furniture is not limited to steam bending or particular wood type, there is other method and material can be adopted for curve design.

Motion Chair, Alan Kaniarz

3.6 Precedent 06

ExLaB 4.0 Timber Steam Bending Experiment

Timber Furniture Workshop (28)

ExLaB

Timber Furniture Workshop (29)

(1)

Timber selection is crucial for steam bending; the side grain has to be as straight as possible and with no knots.

(1) At Timber Revival selecting American oak, timber revival provides dressed timber relatively more straightforward to tell the grain direction.

(2) At Britton Timber to select American maple since Timber Revival does not have any. Compare to TR, Britton timber are undressed, it took us more than an hour to select the straightest grain.

(2)

4.1 Timber Selection

AJ - 01

ExLaB

Timber Furniture Workshop (30)

(1)

(2)

(3)

(1) Bandsawing Maple into different thickness (4mm, 6mm, 8mm, 10mm, 12mm, and 15mm) for testing (2) Soaking timber in PVC Pipe (3) Learning from steam bending from the stool exercise, it is important to clamp down one edge of the metal compression strap to the table before bending action and reserve the exact thickness for the timber to slot in.

4.2 Steam Bending Preparation

AJ - 01

ExLaB

Timber Furniture Workshop (31)

We designed two different moulds for the stool exercise; one with a larger radius and the other relatively tighter. We decided to test the maple with the tighter one, which American oak failed to bend, to compare the possibility of bending between oak and maple.

Result: with the tighter mould oak can only bend up to 5mm, but maple can go up to 10mm. With the larger radius mould oak can bend up to 10mm with a fixable split at the turning point; on the other hand, maple can to 15mm with fixable split ends at the turning point.

(1)

(2)

(1) Larger radius mould (2) Tighter radius mould (circled - selected bending corner)

4.2 Steam Bending Preparation

AJ - 01

ExLaB

Timber Furniture Workshop (32)

(1)

(3)

(1) 4mm Maple Bending (2) 6mm Maple Bending (3) Spring back comparrison - 4mm have a greater spring back than 6mm (2)

4.3 American Maple Width and Thickness Experiment

AJ - 01

ExLaB

Timber Furniture Workshop (33)

(1)

(1) 8mm Maple Bending (2) 10mm Maple Bending (2)

4.3 American Maple Width and Thickness Experiment

AJ - 01

ExLaB

Timber Furniture Workshop (34)

(1)

(1) 12mm Maple Bending - First try failed due to radius being too small for the thickness and grain not straight (2) 15mm Maple Bending - First try failed due to radius being too small for the thickness and grain not straight Note: at this point, we’re unable to source American Maple, so we are using leftover pieces from the workshop; therefore, grain aren’t selected.

(2)

4.3 American Maple Width and Thickness Experiment

AJ - 01

ExLaB

(1)

Timber Furniture Workshop (35)

(2)

(3) (1) Additional cloth compression tape added behind metal strap to have extra compression strength and uses to secure the two metal strap together ensures there is no gap in between.

(2) 12mm Maple Bending - Second try considered successful split at the turning is fixable.

(3) 15mm Maple Bending - Second try considered successful split at the corner is fixable, but grain selection has to be more careful.

4.3 American Maple Width and Thickness Experiment

AJ - 01

ExLaB

Timber Furniture Workshop (36)

(1)

(1) With the same radius bending (left to right 4mm, 6mm, 8mm, 10mm). All bends are successful, and I realized the thicker the timber is the less spring back happened after removing the timber from the mould.

4.3 American Maple Width and Thickness Experiment

AJ - 01

ExLaB

Timber Furniture Workshop (37)

Joining steam bending timber strip has been an ongoing consideration for future design. Based on past experiment beside domino joint (need a minimum of 12mm thickness) or horizontal bracing connection (stool exercise) can be used as a connection between strips there’s no other option to connect the strips. Therefore, I decided to make the connection between strip before steam bending it to resolve future connection issues between strips.

American Oak - “Half Lap” and “Tongue and Groove” Connection

ExLaB

Timber Furniture Workshop (38)

(1)

(2)

(3)

(1) Using table router to create a half lap joint (2) When timber is taken out from the steamer after two days soaking and two hours steaming the moist has completely expended the timber, and the half-lap cannot match up anymore. (3) Even the half-lap does not match up anymore; I still decided to bend it to test the timber’s strength. However, the half-lap part became too week and snapped right away.

4.4 American Oak - Half Lap Connection

ExLaB

Timber Furniture Workshop (39)

(1)

(2)

(1) Similar to half-lap joint I use table router (different cutting head) to create tongue and groove connection between two timber strips. (2) When timber is taken out from the steamer after two days soaking and two hours steaming the moist has completely expended the timber, the tongue and groove connection cannot slot in anymore.

4.5 American Oak - Tongue and Groove Connection

ExLaB

Timber Furniture Workshop (40)

From my sketches for the final chair design, I realized tight curve are involved in the design. I learned that the tight curve in my sketches is not possible to achieve with 12mm timber thickness from several experiments. Therefore, lamination is considered and experimented in advance.

3mm - 12mm American Oak and Maple Lamination

ExLaB

(1)

Timber Furniture Workshop (41)

(2)

(3)

(4)

(1) Mould used to bend 3mm (thickness) x 4 maple lamination (2) All timber is successfully bent. (3) Un-uniformed end accrues due to bending curve. For final design lamination bending (a) a stop block is needed at one end to ensure one end is flat (b) extra length need to be reserve to unify the end later. (c) need a positive and negative mould to clamp the bending timber, so clamp mark does not get on to timber surface. (4) 3mm maple for lamination been soaked for 2 days and steamed for 1.5 hours due to moist its warping.

4.6 American Maple - 3mm x 4 - 12mm Lamination

ExLaB

(1)

Timber Furniture Workshop (42)

(2)

(1) The same mould as previously used on 3mm (thickness) x 4 oak lamination (2) All timber are successfully bent. (3) 3mm oak strip for lamination been soaked for 3 days and steamed for 1.5 hours due to moist and heat its warping even cracked.

Note: Future lamination bending timber cannot soak more than a day and steamed more than 1.5 hours.

4.7 American Oak - 3mm x 4 - 12mm Lamination

(3)

ExLaB

Timber Furniture Workshop (43)

Comparison between maple and American oak - oak has a more twisting action. Maple keeps the shape better.

Note: For final design drying rack is need to prevent spring back and need two positive and negative mould one for bending the other for laminating (gluing)

American Oak vs. Maple Lamination

ExLaB

Timber Furniture Workshop (44)

4.8 Domino Joint on Curve Timber 10mm

ExLaB

(1)

Timber Furniture Workshop (45)

(2)

(1) Clamping 10mm thick curved timber strip on to table (2) Aiming and testing multiple time to get the right spot for domino joint (3) Result - minimum thickness for the smallest domino joint (4mm) to fit should be 12 mm thick timber so that the domino joint won’t expend the top and bottom surface of the timber and more rigid.

Note: For more wavy curve, jigs are needed for clamping and create a flat surface for domino joint to fit in.

4.8 Domino Joint on Curve Timber 10mm

(3)

ExLaB 5.0 Final Design Iterations and Vision

Timber Furniture Workshop (46)

ExLaB

Timber Furniture Workshop (47)

5.1 Design Iterations

ExLaB

Timber Furniture Workshop (48)

5.1 Design Iterations

ExLaB

Timber Furniture Workshop (49)

Upon different design iteration, the final two design iteration

I’ve

selected for my final chair production shown on the left.

Left

Maximum 3 bends

4 connections

Right

Maximum 6 bends

6 connnection

Base on remaining time for final design production, past experiment on steam bending, experiment on connection method, risk on error and amount of weak point in design - The design on the right is what I decided to go for.

5.1 Design Iterations

ExLaB

Timber Furniture Workshop (50)

5.1 Design Iterations

ExLaB

Timber Furniture Workshop (51)

After 3D modelling and consultation with Josh and Christina, making the base stool completely fit to the steam bending curve is a better design. Base on the stability and connecting method removing the gap will be more stable, and the building of

connection

will

be

more

fesable.

The final design is a combination of this and page 47 sketches.

5.1 Design Iterations

ExLaB

Timber Furniture Workshop (52)

5.2 Final Chair Design Dimention

ExLaB

Timber Furniture Workshop (53)

Lamination curve

Steam bending double curve

100mm Maximize each strip’s width to reduce the amount of connection, and minimize the differences between each strip. Also, showcase the maple pattern better.

12 mm

(1)

Base on experiment on slightly smaller radius - 12mm is the minimum thickness for 4mm domino joints to connect and the result for steam bending have tiny split at the corner but can be glue back and sand down.

5.3 Double Bend

ExLaB

Timber Furniture Workshop (54)

Lamination curve

Steam bending single curve - A

Steam bending single curve - B (1)

5.4 Single Bend - Back up Plan

ExLaB

Timber Furniture Workshop (55)

(1) Half lap joint - between lamination curve and double curve strip

(2) Half lap joint - between lamination curve and two single bend strip (A & B)

5.5 Connnection Between Curves - Half Lap Connection

ExLaB

Timber Furniture Workshop (56)

(1) Domino Joints (4mm) for 2 strips

(2) Domino Joints (4mm) for 3 strips

5.6 Connnection Between Strips - Domino Joints

ExLaB

Timber Furniture Workshop (57)

Connection method between steam bending seating to base stand - Mostise and tenon

5.7 Connnection to Base Stand - Mortise and Tenon

ExLaB 6.0 Final Design Preparation

Timber Furniture Workshop (58)

ExLaB

Timber Furniture Workshop (59)

First Clapping Spot

dowels to fix the mould to base board for accurarte bending between each strips Metal strap over lap in the center of the timber strip and placing at the outter side of bending curve to compress the timber bending and hold timber curving in place.

Stop Block / Compression Strap handle - secure timber and metal strap in place.

Staring point for double / two directional bending - in this way metal strap can be secure on the outer face of the curve for both direction bending.

Custom make double bend curve, instead of bending from one end of timber to the other end. The two-directional bends will start from the centre of the timber with metal compression strap covering both sideS of the timber (outer part of the curve).

6.1 Double Curve Bending - Mould Design

ExLaB

Timber Furniture Workshop (60) 12mm MDF Board - act as horizontal bracing to make sure the dowel remain straight at the top so that each timber strip will be as identical as poosible for more seamless finish after connecting and less sanding.

spring back direction

spring back direction

Dowel- prevent Spring back Dowel- hold the curve shape Dowel- make sure this part is flat Dowel- hold the curve shape Dowel- prevent Spring back

6.2 Double Curve Bending - Drying Rack

ExLaB

Timber Furniture Workshop (61) Laminating 4mm x 3 Steam and bend togeter

2nd clamp

Staring Point 1st clamp

Push in force to prevent spring back

Push

up

force

to

prevent spring back

Stoping end to ensure one

Final Clamp

end of lamination is flat Fix to workshop bench

Lamination Steambending Mould work as Gluing Mould too - Possitive and Negative mould for better clamping and avoid clamp mark on timber.

6.3 Lamination Bending - Mould and Drying Rack

Lamination Drying Rack

ExLaB

Timber Furniture Workshop (62)

(1)

(2)

(3)

(1) Bandsawing timber strips to around 4.5mm thickness (2) uses drum sander to gradually sand it down to 4mm all timber strips are sanded down into same thickness (3) sectioning into 5 different batches for soaking and steam bending. For the top and bottom layer of lamination, the design intention is to book match the timber grain; therefore labelling and ordering it’s crucial.

6.4 Preparation for Lamination - Top Part

ExLaB

(1)

Timber Furniture Workshop (63)

(2)

(1) Every 5 strips of timber are band saw from the same timber section, and labelled and match while cutting, therefore book matching went smoothly. At first, I decided to use 1A5A (Left) for the top layer base on the top grain before cutting, however after splitting all the grain under section C; it is a lot nicer and showcases the maple pattern better. (2) The book match pattern I have decided to put on the top.

Preparation for Lamination - Head Rest - Book Matching

ExLaB

(1)

Timber Furniture Workshop (64)

(2)

(3)

(4)

For the making of the base stand for my final chair design, the intention was to use leftover cuts, or parts that are not suitable for steam bending form the Maple we bought to produce less leftover timber as possible.

(1) Length that is too short for my steam bending strip (2) edges that are too damaged can be placed at the base corner and later be filleted (3) grains at the end of the timber piece that is not straight (4) places with knots that are not suitable for steam bending.

6.5 Preparation for Base Stand

ExLaB 7.0 Reflection Part I

The process of steam bending is generally not sustainable for the following reason. First of all, the most crucial part of steam bending is the selection of timber grain, the timber we selected from timber yard is relatively straight already. However, some section the grains are not straight for steam bending, and those parts become offcuts. Secondly, for my design each strip width is 100mm, therefore the timber board that is bought is around 150mm - 170 mm, the remaining again become offcuts. Thirdly, the water resource and energy use to soak and steam the timber compare to other timber work steam bending uses extra energy and resources. Finally, additional material is needed for steam bendings, such as metal compression strap, cloth compression tape, MDF mould, drying rack, lamination steam bend gluing, and lots of testing before the final design complete. -----(Nect Page)

Reflection

Timber Furniture Workshop (65)

ExLaB

Timber Furniture Workshop (66)

Apart from soaking and steaming energy consumption and

(5)

testing

alone

timber

can’t

avoid

the

remaining

part

of

my

Instead

of

I

worked

maybe

the

using with

the

full

others

so

timber

panel

offcuts

for

me

design, I tried to reduce as much waste as possible.

but

(1)

reusing

past

(6) Reduce the amount of mould I need in my design,

mould

for

bending.

my initial design needed up to 6 moulds I decided to

(2)

Making

and

re-assemble

testing

my

timber

on

strip

as

steam wide

as

possible

for

right

dimension

of

other’s

design

change my design so that I only use two moulds only

steam bending, so less timber goes to dust during the

(7)

cutting also less sanding is needed after connecting

is to create a double bend / two-directional bend for

strip

together

the

spring

back,

(3)

Cutting

design, the

so

(narrow

which strip less

cutting

strip

more

the

surface

make as

thick

timber (2mm

does gone

not

possible to for

on

lounge

the

mould

chair.

with

thoughts,

However,

without

my

Final

testing,

design

I’m

not

alined.)

sure

for

go to waste if the double bend failed, I designed my

dust each

the

during

mould

if

to

it

will

break

work

apart

or

not.

into

To

two

not

let

the

individual

mould

moulds.

cut.)

(8) As mentioned before, the design of my lounge chair

(4) Plan out all the dimension to exact and include blade

base stand is using all the offcuts or not suitable part

thickness, so the Timber board fully used and fewer offcuts.

of the maple for steam bending.

Reflection

process

as

variation

Design

ExLaB 8.0 Final Design

Timber Furniture Workshop (67)

ExLaB

Timber Furniture Workshop (68)

First

try

on

steam

bending

double

bend.

(1) Placing in the metal compression in the right spot for preparation (2) First try of steam bend double bend considered successful However, there is some minor adjustment need to be made before the final bend.

Adjustment: a) compression metal strap is not needed, due to timber double bend is bending two different direction; therefore, the timber itself is doing both tension and compression. b) starting point of the timber for bending need to be adjusted. Originally I wanted to place the timber in the centre and try to bend two directions at the same time; however the placement will be inaccurate between different strips.

(1)

(2)

c) Timber blocks as a replacement for the metal strap.

The timber block will protect the maple and even the force from the clap to prevent timber curving from the clamp force point. d) Instead of bending the timber strip with our own force, let the clamp do the bending.

8.1 Steam Bending - Double Bend Test

ExLaB

Timber Furniture Workshop (69)

(1)

(2)

(3)

From testing experience (1) mould work needs to be screw on to the table for an easier and more se-cure bend. (2) successful bend - compare to the test, this time I start from the backrest part, and when timber is halfway bent, the second part of the mould will be set in place. (3) Timber blocks - help even the clamp force.

8.1 Steam Bending - Double Bend

ExLaB

Timber Furniture Workshop (70)

Spring

back

is

unavoidable

with

(1) Spring back after 2 hours resting on the mould.

(1)

8.1 Steam Bending - Double Bend Spring Back

steam

bending.

ExLaB

Timber Furniture Workshop (71)

(1)

(2) Due to Covid 19, a sudden lockdown was announced. The day before the 5 days lockdown, I tried to bend 2 strips for my final design. However, due to time constraints, one is resting on the mould for 2 hours and transferred to the drying rack and rest for 5 days; the other rests on mould for 5 days. Therefore to make the curve as similar as possible, the first strip needs to be re-steam and re-bend.

(1) The difference between 2 strips with different resting and drying time and condition. (2) The strip on the left in (1), is soaked for 30 mins and steamed for 1 hr – how much straighter it becomes is shocking.

8.1 Steam Bending - Double Bend Re-Steaming

ExLaB

Timber Furniture Workshop (72)

(1)

(2)

Drying rack is one of the most critical elements in steam bending.

(1) Curve shape with CNC drilled holes for 16mm dowels to fit in. (2) placing the first steam bend in to prevent and keep the steam bend shape. (3) the end bit is the most crucial place to prevent and stop spring back.

8.1 Steam Bending - Double Bend Drying Rack

(3)

ExLaB

Timber Furniture Workshop (73)

(1)

(2)

(3)

After the testing and ispring back issues, I decided to bend one per day and let it rest on the mould for 24 hours before transfering to the drying rack.

(2)

(1) placing steam bend with mould under the sun to dry and form the shape faster. (2) uses clamp and block to aline the timber strip and make it as identical as possible. (3) All five steam bend strips ends up being pretty identical, however is not similar enough to be place side by side.

8.1 Steam Bending - Double Bend Drying Rack

ExLaB

Timber Furniture Workshop (74)

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Due to soaking, steaming and bending – the bent pieces is not planar. Running it on the planar is necessary to ensure there is a flat reference for future connection.

(1) Going through the planar – freehanded, as the curves of the piece is diverse, at all time the edge should be touching the fence (2) Going through the thicknesser once one is it flat – done through the planar

8.1 Steam Bending - Double Bend Planner Edges

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Timber Furniture Workshop (75)

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(1) Using CNC cut MDF as a mould for the bent lamination. 3 x 4mm Maple is soaked for 1 night, steamed for 1 hour before being bent on the mould (2) Mould is screwed to a board to give stability when bending – which helps reduce the number of people needed.

(3) To ensure the process is sped up, two identical moulds are used.

(4) The outcome of the bent lamination

8.2 Steam Bending - Lamination Bending

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ExLaB

Timber Furniture Workshop (76)

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To ensure that the Epoxy does not stick to the mould – the internal layer is protected with clear tapes Mixing Part A and Part B epoxy at a 2:1 ratio Result of lamination with Epoxy as adhesive – barely any spring back Using Epoxy as adhesive requires a lot of effort in cleaning it up

8.2 Steam Bending - Lamination Bending Glueing

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Timber Furniture Workshop (77)

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However, the third and fourth bent failed not due to the steam bending process due to the Epoxy not holding the lamination shape.

A couple of reason why it failed: - Epoxy might not be mixed with the correct ratio (unlikely as Arthur’s lamination worked with the same batch of the epoxy mixture) - Timber might not be thoroughly dried before applying Epoxy - The heat from the drying rack might be too aggressive?

(1) The difference in lamination – bottom two, success and the top two are failures (2) Attempted to fix with West System liquid epoxy – it holds the shape back but did not fill the gap thoroughly (3) Attempted to fix the gap with filler and glue – with maple sawdust; however, the colour was too dark

8.2 Steam Bending - Lamination Bending Failing

ExLaB

Timber Furniture Workshop (78)

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(1) Four of the lamination side by side (2) Cleaning up with handheld sander to remove any epoxy stains

8.2 Steam Bending - Lamination Bending Cleaning Up

ExLaB

Timber Furniture Workshop (79)

Review The original intention was to have all five bent pieces flushed to each other. However, due to time constraints, issues procuring the mould, and lamination failure, there is not enough time for the wood to rest in the drying rack.

Even though all the pieces were left in the drying rack and clamped to ensure that each side is flushing, it was only 80% identical as it did not go through the recommended five days resting time.

At this point, I decided to reduce to 4 bent pieces instead of 5 pieces. This is due to the time constraint, and pursuing 5 pieces, will take up an additional two days of bending and laminating.

Upon consulting with Josh, it might be better to split them apart instead of forcefully flushing all of them. Although flushing all of them is possible, the outcome will leave certain spots extremely thin due to the sanding process.

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8.1 Steam Bending - Double Bend Change In Design

ExLaB

Timber Furniture Workshop (80)

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8.3 Base Stand - Base Block

While waiting for the MDF to be delivered and CNC-ed, I laminated the base stand.

(1) Offcuts were glued separately to dimension (2) Gluing it up into the final basic form (3) Cleaning it up with a scraper (4) Gluing the corner pieces to thicken the parts where it is going to be filleted

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Timber Furniture Workshop (81)

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Once assembled, cut through the band saw to ensure that one side is a flat reference Marking out the fillet based on the design Bandsawing it close to the desired fillet radius Using the disk sander to smoothen the fillet

8.3 Base Stand - Shapping

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Timber Furniture Workshop (82)

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(1) Marking out the slit (2) Angling the table saw blade to the slit angle (3) Cutting two edges reference line on the table saw (4) Using the band saw to cut the curves as close as possible (5) Chiselling the curvature to ensure its smooth (6) Using a cardboard tube taped with 80 grit sanding paper to smoothen out.

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8.3 Base Stand - Side Cut

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Timber Furniture Workshop (83)

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(1) Marking out the seat curvature to the base stand (2) Cutting it on the band saw (3) Using the carving tool to match as much as possible to the seat curvature

8.3 Base Stand - Cutting Curve Base on Steam Bending

ExLaB

Timber Furniture Workshop (84)

Review - In general, the experience of making the base stand went somewhat according to plan.

However, if I were to do it again – I would not fillet the stand before figuring out the seat curvature and the sidecut. Filleting the edges was a decision as I did not want to waste time waiting for the MDF and my bending mould to be CNC-ed.

8.3 Base Stand - Review

ExLaB

Timber Furniture Workshop (85)

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Half Lap Joint is the connection method I have decided to use to connect separate section of strips. I have designed the connection base on the curve’s facing and how it will fit and be secure on to the machine bed.

(1) using the table saw for extension section of half-lap - quick set up and clean cut (2) use a small hand planner to make sure the half-lap is clean and flat.

(3) for the curve part, at first, I wanted to do it on the table saw; however, to secure the timber is too complicated and sketchy, (4) Setting on the router table is more secure, faster, and more accurate.

8.4 Connection - Half Lap

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ExLaB

Timber Furniture Workshop (86)

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(1) Layout wast part of the strip and taped with blue masking tape - prepare for glue up (2) gluing all individual strip all together

8.4 Connection - Half Lap

ExLaB

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Timber Furniture Workshop (87)

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As mentioned before, the design has changed to splitting the strip apart; after thinking, I have decided to split each strip 10mm apart from each other. Therefore custom domino joint need to be made, also a space bar to increase gluing surface.

The timber strip is 12mm thick; therefore, to make sure the domino can be placed in the centre domino machine is set to 16mm and add a 2mm perspex as a pack to make sure the domino is in the centre of 12mm timber strip.

(1) after cutting timber to domino size 5mm thick and 19mm wide, use the router machine to make domino pointy corner.

(2) Custom domino (3) Clamping all strip tight and aline to make out domino spot (4) Clamp-on tp the table tightly for domino (5) Final result for domino each side have six domino connection

8.4 Connection - Domino Joint

ExLaB

Timber Furniture Workshop (88)

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Set up for making domino for the space bar.

Same 2mm perspex is placed under space bar to get to the centre.

(1) At first, I decided not to cut the space bar and do all the domino in one goal; however, it is too hard to balance and make sure the space bar strip is entire flat on the strip (2) Therefore, space bars are cut into the right dimension (50mm) before dominoing

8.4 Connection - Space Block Domino Joint

ExLaB

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Timber Furniture Workshop (89)

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Assembling the strips (1) Before gluing in the domino space bar and connecting the strip together; blue masking tape is tape around the connecting part to prevent glue squeezing and less cleaning later on.

(2) glue in domino first (3) then space block (4) connect 2 strips first (5) combining all 4 strips

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8.4 Connection - Connecting Strips

ExLaB

Timber Furniture Workshop (90)

After the glue are set for 12 hours plus, I use the handheld sanding machine to sand down the space bar. The timber strips are 12mm, and the space bar are made to 15mm to have extra meat to level the space bar between the timber strip to flat.

8.4 Connection - Leveling Strips

ExLaB

Timber Furniture Workshop (91)

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(1) space for the mortise to go into the base stand (2) laminating offcuts of American oak (3) planner the American oak to fit (4) use top-grain side as the facing to connect to the chair body - to have an easier cutting and better gluing surface.

8.4 Connection - Mortise and Tenon

ExLaB

Timber Furniture Workshop (92)

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(1) Mark out seat curve (2) Bandsaw the curve

8.4 Connection - Mortise and Tenon Match with Steam Bend Curve

ExLaB

Timber Furniture Workshop (93)

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(1) Dry clamp the mortise to the chair body and mark out the right spot (2) Use blue masking tape mark out the position and protect the timber from glue squeezing out while clamping (3) use a plastic straw to clean the squeezed-out epoxy I decided to use epoxy instead of regular timber glue because the mortise did not 100% match to chair body; therefore, epoxy will have the ability to fill out the gaps

8.4 Connection - Mortise and Tenon Assembling

ExLaB

Timber Furniture Workshop (94)

The mortise I’ve made fit tightly into the base stand; I need to hammer it so it would fit in. Therefore there is no glue needed.

However, when I’m making the mortise, i only match the mortise to the body but not the base stand. Therefore, it did not match the base stand, creating a floating effect (Turns in into my initial design accidentally).

I test seat on it and it is stable.

8.4 Connection - Mortise and Tenon

ExLaB

Timber Furniture Workshop (95)

I decided to apply the Evolution Raw Light Stain as the first layer of finishing to retain the maple’s light tone.

8.5 Apply Finishing

ExLaB 9.0 Final Reflection

Timber Furniture Workshop (96)

ExLaB

Timber Furniture Workshop (97)

The process of making the final furniture piece - Float involves a lot of emotional ups and downs, also much computerization in terms of design. There are definitely many moments that I wanted to give up; even though the final result is not perfect, but for my very first furniture making is worth it, and the hard work paid off. During the making process, I have learned a lot about steam bending, different wood performance, various machine, detailing, connection making and designing mould and drying rack.

The biggest take away from the making is I learned how thinking on the spot when things do not go the way I planed, compromise with the errors and make it work.

Final Reflection