Exlab_Timber Furniture Workshop

ExLaB Ka Wing Karen Tsui 657638 Mini Wafer

exlab.org

Design Journal 28/09/2019

Experimental Design Lab (1)

ExLaB

Experimental Design Lab (2)

Contents 1.0 Introduction 2.0 Exercise 1: Plant Stand 3.0 Exercise 2: Laser Cutter

3 4-9 10-33

4.0 Eercise 3: Veneer

34-49

5.0 Final: Mini Wafer

51-99

Table of contents

ExLaB 1.0 Introduction

Experimental Design Lab (3)

“With informed consideration of materiality, anthropometrics and fabrication techniques, students will explore ways of delivering a furniture piece that addresses a thematic of ‘The body at rest.’ This ExLab subject values experimentation with making processes, tools, and materials to inform the design process. A resulting final piece should highlight this experimentation process, demonstrate exemplary craft, and serve as a functioning seat for one person.

Students will be exposed to a wide range of making techniques, developing skills in hand-tool usage and modern woodworking equipment. Melbourne makers will be invited to share their work and participate in critiques to progress the students work.”

1.0

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1.0

Experimental Design Lab (4)

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Experimental Design Lab (4)

2.0 2.0

Exercise 1: Plant Stand

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Experimental Design Lab (5)

2.0 Spinner Objective:

Explore and use most of the machines in Machine Workshop. Both Monica and I did not have any experience on woodworking before.

Design Agenda: Instead of making traditional frame for the plant stand, symmetrical three-legs stand with minimal joints is designed. Design is inspired from spinner and various woodworking joints. There are 3 sets of components interlocking each other. In total, 8 pieces of timber create Spinner. We tried most of the machines and hand tool, chisel.

(1) Spinner, Monica, Karen, 2019

2.0

Exercise 1: Plant Stand

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Experimental Design Lab (6)

Research:

Super-strong mitered half-laps https://www.woodmagazine.com/woodworking-tips/ techniques/joinery/half-laps

2.0

Exercise 1: Plant Stand

Rationale:

Component

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Experimental Design Lab (7)

1. Legs are connected at the edge but it will looks too wide

2.0

2. Push the leg 100mm in. Also, create split edge to look lighter and extend tenon as a lock for plants

Exercise 1: Plant Stand

3. change bracing into a clip as it is shaking

4. Final

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Reflection:

Experimental Design Lab (8)

Composition:

(1)

(4)

1. As the plant stand is 750mm tall, top and leg pieces are designed as 35x50x280 and 16x50x750 to create a solid stand. However, after making the products, it seems too bulky because of the intended small plant pots (150mm wide).

Joinery: 2. Joints are hidden by the plant pot.

Language could be consistent for the whole design, spinning not only on the top piece but also for the legs.

For a quick fix, maybe adding three small dowels to lift up the plant pot to reveal the joint.

(2)

(5)

3. Joints are not cut accurately because of inexperience on operating machines and tools. Josh suggested us to use gap filler to make the joints obvious. We collect timber dust and mix with glue to fill the gaps.

Design:

(3)

(6)

(1) Preparing cut, (2) sketch, (3)Using chisel to clean the holes, (4) Timber dust mix in glue to act as a gap filler, (5) top view, (6) Tenon joint.

2.0

Exercise 1: Plant Stand

As Monica and I do not have any experience on it, it takes us so long to make those simple cuts. After that, I deeply appreciate every cut, joinery or even how designer orient their material to show the beauty of it.

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2.0

Experimental Design Lab (9)

Exercise 1: Plant Stand

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2.0

Experimental Design Lab (10)

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Experimental Design Lab (10)

3.0 3.0

Exercise 2: Laser Cutter

photograph/ Charlie White

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3.0 Sieve

Experimental Design Lab (11)

Objective: Create stool mainly on laser cutter

Design Agenda: Exploring repetitive elements of design and thickness of materials that can could hold weight. Also, building 3D models that have precise interlocking or set joints.

(1) Final Design. Sieve, Monica, Karen, 2019 photograph/ Charlie White

3.0

Exercise 2: Laser Cutter

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Research:

Experimental Design Lab (12)

The significant benefits of laser cutter are accuracy and time. Joints and timber piece could be made perfectly.

However, the thickness of material and form (3D) are limited.

(1) We looked into th precedent to see how a supplementary block can space and hold the thin veneer in aesthetic way.

(2) Weaving woven strips can create not only a 2D pattern, but it can also be a 3D element. Although (2) can not be seated, but only 12 strips of veneer can becomes beautiful sculpture.

(1) https://www.pinterest.com.au/pin/536772849338270907/

(2) https://www.pinterest.com.au/pin/378091331217153950/

3.0

Exercise 2: Laser Cutter

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Experimental Design Lab (13)

3.1 3.0

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Test #1 This is the first prototype made in the first week for this exercise. The idea is to use a series of bent strips to hold weight.

We use 3mm MDF for this experiment with the left- over 2.7mm ply strips from another test for spacing.

Every piece will be connected and squeeze together for seat.

(1) Prototype, Monica, Karen, 2019

3.1

Exercise 2: Laser Cutter

After the test, when we look at the prototype, the burnt mark on the timber is bad.

Also, it looks wonky.

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Experimental Design Lab (14)

(1)

(4)

(7)

(2)

(5)

(8)

(3)

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(1) Process, (2) Using leftover ply for spacing, (3) Standing the element right after taking them out, it slopes downwards which is not right, (4) Laying out the strips, (5) Leftover pieces from another test, (6) The joint line is too close to the edge, it breaks the base when elements are pushed together, (7) Jointing elements using glue; again too little contact surface, (8) Stabalize them using tape, (9) Test, it works!, but not stable.

3.1

Exercise 2: Laser Cutter

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Experimental Design Lab (15) Stool failed because 1. the curvature is wrong and the cantilever is too much. When the force applied on top, load is off-center.

2. Wood strips is too small and thin. When width is squeezed and connected by wood strips, the base tilted and the top is shaking. 40mm spacing are too wide.

3. 1 layer of bottom piece is not enough to hold the above strips.

3.1

Exercise 2: Laser Cutter

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Experimental Design Lab (16)

3.2 3.2

photograph/ Charlie White

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Experimental Design Lab (17)

TEST #2 The second idea is to test the interlocking performance, that we always use when doing laser cutting work.

The design is to create a small stool that could be seatable. We are referencing a “T� shape and mushroom to build the model.

(1) Prototype, Monica, Karen, 2019

3.2

Exercise 2: Laser Cutter

Stool is stable because of the interlocking and cross joining with next element.

However, the periphery of the top, 2.7mm plywood is too thin and brittle with the joint cut. Also, the burnt mark is obvious.

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Experimental Design Lab (18)

(1)

(4)

(2)

(5)

(3)

(6)

(1) Layout, (2) Elements, (3) Assembling them with orders, (4) Using mallet to knock pieces together, (5) Testing, (6) close up of joints.

3.2

Exercise 2: Laser Cutter

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Experimental Design Lab (19)

photograph/ Charlie White

3.2

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Experimental Design Lab (20)

3.3 3.3

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TEST #3 The third stool is taking the idea of luggage rack and a cathedral arch for the structure.

A strip of square profile wood is used to connect the one -way crossing elements.

The top mat is used as a sitting sheet with a bit of flexibility. That is achieved by carving a pattern on the timber with holes to loosen it up.

(1) Prototype, Monica, Karen, 2019

3.3

Exercise 2: Laser Cutter

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Experimental Design Lab (22)

It fails because there is no flat surface distribute loads to the side (1).

Bottom should be braced to lock the position since the pressure on top will shifts the side timber to center (2).

(1)

(3)

(2)

(4)

(1) (2) (4) Load test and Sitting test, (3) Gluing element together

3.3

Exercise 2: Laser Cutter

(1)

(2)

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Experimental Design Lab (23)

3.4 3.4

photograph/ Charlie White

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Experimental Design Lab (24)

TEST #4:

Since we laser cut four different iterations of the “sieve� to test its best strength, we chose the remaining two for form testing.

3.4

Exercise 2: Laser Cutter

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Experimental Design Lab (25)

(1)

(2)

(3)

(4)

(5)

(1) Sit test. (2) Gluing two stool together. (3) Inverted seat possibility. (4) Test. (5) Using the sander to sand a flat surface, but taking too much off.

3.4

Exercise 2: Laser Cutter

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Experimental Design Lab (26)

photograph/ Charlie White

3.4

Exercise 2: Laser Cutter

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Experimental Design Lab (27)

3.5 3.5

Exercise 2: Laser Cutter

photograph/ Charlie White

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Experimental Design Lab (28)

Bending

17mm

20mm

25mm

30mm

Spacing

Test #1 is preferred

After first review, for further development.

(1) Sieve, Monica, Karen, 2019

3.5

Exercise 2: Laser Cutter

As we are assigned to use laser cutter, it will take at least a day or two to get the print job done, thus, we made 4 varations for testing in one go. Reflecting the issues from the last stool, we create different spacing and bending degree to see which one has the best performance. The final chosen one is shown above.

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(1)

Experimental Design Lab (29)

(2)

(4)

(6)

(3)

(5)

(7)

(1) 4 variations, (2) plywood with differnet colours (not in our control), (3) testing performance and assembling, (4) angled timber block is used for spacing, 20x10x35mm, we choose light colour pine to contrast the main body. (5) let the glue dry, (6) pattern following the profile of the stool, (7) when squeezing them, using 20mm spacing base, the wood strips are twisted and not stable.

3.5

Exercise 2: Laser Cutter

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Experimental Design Lab (30)

Reflection: 1. For the laser cutting machine, it could cut materials accurately with all curves in any angle. It could do intricate joints and it is good for prototyping. However, the burnt marks on the edge of each piece is very obvious. In my case, sanding the edge could not get a sharp and clean profile of the element. Also, the luna plywood will chip out.

2. Clean up the glue mark!! Since there is a lot of tiny block, need to make sure it is cleaned with damp cloth before the glue set.

3. Should try different thickness of timber since the material is 2.7mm thick only, and ‘7’ shaped of main structural element to take load, thicker timber would be better. However, we run out of time to test thicker timber using laser cutter as the first batch takes us 3 days to get them printed. Therefore, it is ashamed we could not test that.

4. Individual timber spacing block are not aligned perfectly because we place it without guidelines. Next time, we should edge or put a mark on each piece for indication. Also, the proportion doesn’t seem great.

Should have a test on that too.

3.5

Exercise 2: Laser Cutter

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Experimental Design Lab (31)

Reflection:

What we learnt from this for boarder design discourse, (1) for the structural load, we could test in different ways such as test on paper, 3D printing if time is the concern. (2) Test!

Never know without testing.

From all the exercise I have been working on, I realise making products/ or even the field of construction consume and waste a lot of materials. For example, to square the timber, few milimeter of timber is lost; to make a perfect timber size for our own project, the end of the timber block might go to the bin; carving is even worse. Therefore, I would like to focus on, how to create a design with less consumption.

3.5

Exercise 2: Laser Cutter

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Experimental Design Lab (32)

photograph/ Charlie

3.5

Exercise 2: Laser Cutter

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Experimental Design Lab (33)

photograph/ Charlie White

3.5

Exercise 2: Laser Cutter

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Experimental Design Lab (34)

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Experimental Design Lab (34)

4.0 4.0

photograph/ Charlie White

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Experimental Design Lab (35)

3.0 Flying Bridge Objective: Create stool veneers

using

2-3mm

Design Agenda: Exploring different ways of using veneers and find a most appropriate one.

Final design concept is using active bending and referencing a bridge design.

(1) Flying Bridge, Monica and Karen, 2019

4.0

Exercise 3: 2mm Veneer

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Test

Experimental Design Lab (36)

(1) Cutting long strips to weave. To maintain its tension and form, we did not steam veneers, however, veneer starts breaking until certain degree has been reached. Also, veneers are too thin to perform as a stool. Extra bracing at the bottom is required to hold in place.

(1)

(2) Results of bending 2-3mm veneer with different hot water soaking time. For softwood, it is better to soak in hot water for 45 mins and then bend in hot water immediately. We did not make any mold but using the bucket as a mould.

Apparently, the bend varies due to no control.

Lever and a mould for bending are required for better quality.

(1)

(3) After soften up timber, we test the twisting performance. Timber could make into different shape. For this case, twist could take up more loads, compared to a normal rectangular strip.

However, to use this technique, other components are needed to hold that up. Also, It could not reach the strength as a structural element taking human’s weight as it is 2mm thick only.

(2)

4.0

(3)

Exercise 3: 2mm Veneer

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Experimental Design Lab (37)

Test (1) Angle cut to lock the bended strip in place.

(2) Natural bending of timber veneer. However, it could not take load in one layer. Also, when pressing downwards, both side expand and nearly break.

(1)

(4)

(2)

(5)

(3)

(6)

(3) Test as a aesthetic joint.

(4)Stacking layers of 2.5mm veneer. It is not visible as it requires lots of material and the overhanging part is fragile.

(5) Softened the timber and create wave pattern by using steel cone. Again, it is not structurally valid.

(6) Same as above, Cruving the timber using everyday’s household stuff. That is a bracket.

4.0

Exercise 3: 2mm Veneer

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Experimental Design Lab (38)

(1)

(3)

(5)

(7)

(2)

(4)

(6)

(8)

(1) Bending American White Oak. Although it is the same thickness as previous, the density of oak is higher and it doesn’t bend well without lever and with the same treatment. (2) Bending long continuous strip using cloth rack. (3) Twist and bend, clamped with clips. (4) Potentially it could be armrest. (5) Different bend with different thickness, width and materials. (6) Testing how to join veneers. (7) Bending (1) using the plant stand. (8) It could bend to form a ball.

4.0

Exercise 3: 2mm Veneer

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Experimental Design Lab (39)

Research reflection:

and

Except the above experiments, we look at using strips as connection. (Left, photos from pinterest) A precedent from internet. We found it interesting since it acts as a “stitich� to an original piece. Thus, we try to test, what if most of the seatable area is made up with this strips (Right).

4.0

Exercise 3: 2mm Veneer

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Experimental Design Lab (40)

Development

(1) After the first crit, David suggest us to keep developing this when the force are applied on the timber. Let the veneer be the structural element.

(2) , (3) sketches, we develop different ideas based on (1).

(1)

(2)

4.0

(4)

(3)

Exercise 3: 2mm Veneer

(5)

(6)

(4), (5) First trial. Instead of letting the force push the pieces downwards, passively, we are interested to use active bending to maximize the strength of timber.

(6) Gluing timber block. It is taking up a lot of timber, therefore we decide to lower the stool.

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Experimental Design Lab (41)

Digital Modelling (1) Testing the structure of main body. Too curvy.

(1)

(4)

(2) Back-up plan, the timber has a small arch in the center to support the upper veneers if needed.

(3) Trying to shape the body (V-shape) to look less bulky but it is not great.

(2)

(5)

(4) Back to the original square plan.

(3)

4.0

(6)

Exercise 3: 2mm Veneer

(5),(6) Using the bending strips as the only structure.

But pieces are disconnected and the curve could not be achieved with active bending.

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Experimental Design Lab (42)

(4)

(5)

(1)

(2)

(3)

(6)

(1) Finalize stool, using curve strips to connect at two sides. The idea is to mirror the curve of the active bended veneers to the main body. (2) How to hold each piece in place using horizontal strip. But it looks bad. (3),(4) Template for cutting. (5) Curves extracted from the main body. (6) Shorten the stool, using square block to connect

4.0

Exercise 3: 2mm Veneer

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Experimental Design Lab (43)

Explanation:

(1) As the concern of waste and consumption, we decide to make 16mm thick timber for each piece and space 16mm each. Also, lower the stool. Originally, we decided to make a big block and carve the inner layer for veneer or one wide piece to hold all veneer strips, but that will take up a lot of materials (p.30 (2, 3). Now, only 8 pieces are needed.

(1)

(4)

Process of testing the curve of walnut. We reuse the waste materials from the bin. The colour is perfect for us because it contrast the body. We trace the curve from the paper to the timber piece for cut.

(2) Using band saw to cut.

(3), (5) Sketches for development.

(4) Clamping all pieces together.

(2)

4.0

(3)

Exercise 3: 2mm Veneer

(5)

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Experimental Design Lab (44)

(3)

(1)

(4)

(6)

(8)

(2)

(5)

(7)

(9)

(1) Not aligned timber. (2) Due to the unsymmetrical joint. (3) Connecting pieces with 2mm strips at side. (4) Enlarged joint. (5) Putting weight to let glue dry. (6) Individual pieces. (7) Hold to let glue dry. (8) Clamping the stool. (9) Curve is set wrong, pieces can’t join perfectly together.

4.0

Exercise 3: 2mm Veneer

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Experimental Design Lab (45)

photograph/ Charlie White

4.0

Exercise 3: 2mm Veneer

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Experimental Design Lab (46)

photograph/ Charlie White

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Exercise 3: 2mm Veneer

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Experimental Design Lab (47)

photograph/ Charlie White

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Exercise 3: 2mm Veneer

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Experimental Design Lab (48)

Exercise 3: 2mm Veneer

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Experimental Design Lab (49)

Reflection:

For the edge connection, there are few fatal mistakes as mentioned before. Also, the quantity of bending strips on top should be controlled. For accurate joint, lasercutter could be used in the future.

Design: As there are few design elements happen at the same time, I should keep the design simple, that is, only bending strips are bent/ with curve in the design. Always one idea in a design instead of a few without focus.

4.0

Exercise 3: 2mm Veneer

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Experimental Design Lab (50)

photograph/ Charlie White

4.0

Exercise 3: 2mm Veneer

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Experimental Design Lab (51)

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5.0 5.0

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Experimental Design Lab (53)

(1) Wafer, Karen, 2019

5.0

Final: Mini Wafer

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Experimental Design Lab (54)

Moodboard:

(3)

(1)

(3)

(2)

(4)

We started the moodboard from week 4. At first, I was interested in the geometry and form of (3), by Overgaard & Dyrman, but after the first few exercises, I know I am not skilled and it will be very difficult for me to produce such a large piece within few weeks. Therefore, I changed the direction to take further experimentation on the materiality from exercise 3, veneer 2-3mm.

The weekly moodboard exercise helps us to develop a range of techniques that we are interested in.

(1) (4) bending precedent. (2) Veneers joining and variations. (3) First precedent, of what I want to pursue in terms of color, joining method, geometry and form.

5.1

Final: Moodboard

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(5)

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(6)

(5), (6), (7) Initial sketches for final furniture piece.

5.1

Final: Moodboard

(7)

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(1)

(2)

(4)

(3)

(5)

(1) repretitive element connected to be a chair. (2) Using brass and leather string connection. (3) joinery, insert and screw. (4) Cult gaia bag, love the simple and elemental expression. (5) More bending, bending whole strip arm and leg.

5.1

Final: Moodboard

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Experimental Design Lab (57)

5.2 Bending: Veneer 2-3mm Objective:

Bending 2-3mm veneer to create a stool or chair

Design Agenda: I decided to use one bending strip as an element to drive the project. From exercise 3, we did a lot of test on bending veneers. I was surprised when these bended elements were layout and stood vertically on the timber, the strength is high. Thus, I would like to keep exploring this aspect of veneers.

5.2

Final: Development

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Experimental Design Lab (58)

(4)

(2)

(3)

(1)

(5)

(1) Test from exercise 3. (2) Insert strips to the base and form a pattern. (3) Base with holes. However, the spacing between them is too close that some of them break while drilling. (4) Pattern. (5) Testing if it could stand by itself. However, it could not because elements are not overlapped, need other frame or support.

5.2

Final: Development

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(1) Prototype 1, Karen, 2019

5.2

Final: Development

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2.0 Chapter Name

(6)

(1)

(2)

(4)

(3)

(5)

(7)

(1) Lasercut the base and test differnt layout or pattern. (2) Laser cut file. (3) Radial position, it does not look tight and stable since pieces are sitting next to each other. (4) “Planting” elements and the pattern is great. (5) Trying to use eyelet to clip the piece and also lock the strip in place. (6) 15mm wide veneer with 3mm holes weaken the strip, rivet does not went well in thin veneer. (7) As I was imagining these are plant shoots, I was cutting the “root” to look more organic.

5.2

Final: Development

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(1) Prototype 1, Karen, 2019

5.2

Final: Development

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Experimental Design Lab (62)

From the previos test, I took it as a seat design, and I developed a series design as following,

5.2

Final: Development

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(1)

Experimental Design Lab (63)

(2)

(3)

(5)

(6)

(7)

(8)

(4)

(9)

(1) Using strips as the cushion for the chair. Insert veneer of the legs to main sitting plate. (2) Varation on chair. (3)(4) Another test on simple design without strips. (5)-(9) Testing How to hold the strips in different ways.

5.2

Final: Development

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Experimental Design Lab (64)

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(1) -(5) Based on a round bucket form to hold the strips, series of structure are explored. (6)-(8) Keeping the design simple with straight legs. (9)-(10). Pattern exploration. (10) is preferred since they are tighter.

5.2

Final: Development

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Experimental Design Lab (65)

Design:

I was taking the overgaard& dyrman design as a precedent and add the cushion idea to this chair.

Hoever, after talking with

David and Josh, it would be more interesting if the direction changed to reduce only one element as the main component of the design.

Hence, I started to test the strips in different way again.

(2)

(1)

(3)

(1) 3D print of the prefered design from the above. (2) Sketches. (3) Digital model of the chair

5.2

Final: Development

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Experimental Design Lab (66)

(3)

(1)

(4)

(2)

(5)

(6)

(7)

(1) (2) Further exploration on how stips connect continuously. (3) (6) adding extra piece as a ring to hold the body in place, does not work without extra fixing elements. (4)(5) Egg whisk to hold piece better. Pin on top, strip at the bottom. (7) Using plastic to hold timber in place. It does not look good.

5.2

Final: Development

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Test:

(1)

(4)

(2)

(5)

(3)

(6)

(1) Start testing if bending the bottom could work. (2) It breaks and difficult to hold other piece in place. (3) One set of element. (4) Jig for bending. (5) Test to connect strip. (6) Other ways of connecting strips together.

5.2

Final: Development

The difficulty of this experimentation is how could I join single elements together without losing the verticality that I am interested in, and also the look of simplicity. These are the tests that I could think of, e.g. connecting strips using plastic, metal eyelets bending the lower part of the strips... However, they are not good solutions since they are the “extra� to the design that are not belong together.

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Experimental Design Lab (68)

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

Iterations (1) Using strip to connect at th middle. (2) Use dowel to connect at the middle part. (3) Mirror element. (4) Using string to connect. (5) Splayed at bottom. (6) Grid pattern, not stable. (7) Making the back strips higher as the support. (8) The pattern is not aligned at the center point, could not join properly without the plate. (9) Final stool with aligned elements. (10) using sqaure strips. (11) Dowels connection. (12) Half-laps for fixing.

5.2

Final: Development

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Experimental Design Lab (69)

(2)

(3)

(1)

(4) Preferred Set. (1) Component, Grid and strips with two holes arrangement. (2) Module. (3) Top view, pattern of bending veneers. (4) Iso.

5.2

Final: Development

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Final Set:

Instead of only 1 loop, taking loop on both ends to make the stool more complete.

1:1 Prototype

5.2

Final: Development

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Failure:

I bought american oak for the entire stool. After cutting all strips, sanding them for smooth surfaces starting to bend them, and just realize 3/4 of them are with cross grain.

Solution: Bought pine from bunnings to save time.

5.2

Final: Development

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Pattern test: (red = american oak; white = pine).

5.2

Final: Development

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5.3

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Final: Development

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Diagram:

Two layers of grid hold the strips in place. Upper dowels (pink) are those with half-laps. This is to make sure when the force is applied on top, it will be more secure.

5.3

Final: Development

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Sketch of jigs and elements

5.3

Final: Building Process

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Process of making jigs

(1) Make a jig to hold 8mm dowel in place for drilling hald laps joint.

(2) (3) Jig in both sides (1)

(4)

(4) Connection of dowels (5) Jig for cutting 8mm dowel

(2)

(5)

(3)

(6)

5.3

Final: Building Process

(6) The timber breaks because the orientation of wood is not parallel to the drill, the long strips spin, and the sharpener (5) is not working well.

ExLaB

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Clamp

Center Line

C. Line

Clamp

Jigs for bending: Marks on jigs for control.

5.3

Final: Building Process

ExLaB

Experimental Design Lab (78)

Jigs for bending: Marks on jigs for control.

5.3

Final: Building Process

ExLaB

(1)

Experimental Design Lab (79)

(2)

(3)

(4)

(1) softening timber in hot water for 40 mins, covered by plastic to reduce heat loss. (2) Clamping strip into place. (3) Using jig to make sure they are aligned.

(4) Prevent chemical reaction with metal clips.

5.3

Final: Building Process

ExLaB

Experimental Design Lab (80)

After bending.

5.3

Final: Building Process

ExLaB

Experimental Design Lab (81)

Gluing strips.

5.3

Final: Building Process

ExLaB

Experimental Design Lab (82)

Marks on the timber due to metal clips.

5.3

Final: Building Process

ExLaB

Experimental Design Lab (83)

Drilling holes on 2 set of strips.

5.3

Final: Building Process

ExLaB

(1)

Experimental Design Lab (84)

(2)

Applying finishing. (1) Hardwax oil. (2) (3) Waiting to dry. (4) Strips.

Final piece: 2 coats on the top and bottom + peripheral strips.

5.3

Final: Building Process

(3)

(4)

ExLaB

5.3

Experimental Design Lab (85)

Final: Building Process

ExLaB

Experimental Design Lab (86)

(1)

(3)

(5)

(2)

(4)

(6)

(1) Making spacers for the stools from 16mm dowels. (2) Cutting 7mm spacer. (3) Jig to cut dowel. (4) Cutted piece. (5) Jig to find the center of dowel. (6) Sanding dowels using Bailey’s jig.

5.3

Final: Building Process

ExLaB

5.3

Experimental Design Lab (87)

Final: Building Process

ExLaB

Experimental Design Lab (88)

Modules Set.

5.3

Final: Building Process

ExLaB

5.3

Experimental Design Lab (89)

Final: Building Process

ExLaB

Experimental Design Lab (90)

(1)

(3)

(2)

(4)

(5)

(1) All the dowels for grid connection. (2) Jigs for half laps. (3) Jigs for cutting holes. (4) Jigs and components for spacers. (5) Cotton Twine for bracing.

5.3

Final: Building Process

ExLaB

Experimental Design Lab (91)

Bracing

Although cotton twine is not rigid enough for cross bracing, it still helps a bit.

(1)

(3)

(2)

(4)

(1) (3) Holding dowels in place. (2) Internal bracing. (4) Spacers.

5.3

Final: Building Process

ExLaB

Experimental Design Lab (92)

(1)

(2)

(1) Joint bracing. (2) Cross bracing diagrams

5.3

Final: Building Process

ExLaB

5.3

Experimental Design Lab (93)

Final: Building Process

ExLaB

5.3

Experimental Design Lab (94)

ExLaB

Experimental Design Lab (95)

photograph/ Charlie White

5.3

Final: Mini Wafer

ExLaB

Experimental Design Lab (96)

photograph/ Charlie White

5.4

Final: Mini Wafer

ExLaB

Experimental Design Lab (97)

Reflection:

The main take-away for me is that “You will never know until you start building it.�

There are too many situations happen when building the stool.

No matter what, I really appreciate all the help from fablab staff. I could not imagine I could build a furniture by myself, especially this course is my first time making furniture or using timber for design.

5.4

Final: Mini Wafer

ExLaB

Experimental Design Lab (98)

photograph/ Charlie White

5.4

Final: Mini Wafer

ExLaB

5.4

Experimental Design Lab (99)

Final: Mini Wafer