Rotomolded Sofa Cum Bed (for small living spaces)

ROTOMOLDED SOFA CUM BED A

S

M

LIVING

A

L

L

ROOM

S

P

FURNITURE

A

C

E

FOR

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DIPLOMA PROJECT Rotomolded Sofa Cum Bed Sponsor: Platypus Design Volume: 1

STUDENT: NEELAM KHETMAR PROGRAMME: Post-Graduate Diploma Programme GUIDE: KRISHNESH MEHTA

2014 INDUSTRIAL DESIGN FACULTY (FURNITURE AND INTERIOR DESIGN)

National Institute of Design Ahmedabad

Copyright @ 2014 Student document publication, meant for Private circulation only. All rights reserved.

Post Graduate Diploma Programme in Design, Furniture and Interior Design, 2011 - 2014, National Institute of Design, Ahmedabad, India.

No part of this document will be reproduced or transmitted in any form or by any means, electronically or mechanically, including photocopying, xerography, and videography recording without written permission from the publisher, Neelam Khetmar and National Institute of Design.

All illustrations and photographs in this document are copyright @ 2013 - 2014 by respective people/organizations.

Edited and designed by – Name: Neelam Khetmar E-mail: neelam.k@nid.edu ; neel200887@gmail.com Processed at National Institute of Design (NID) Paldi, Ahmedabad-380007, Gujarat, India http://nid.edu Printed digitally in Ahmedabad.

August 2014

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Preface

As part of the NID curriculum, all final year students are required to undertake a diploma project which is a full scale design project in the industry. The Diploma Project, which is expected to be of a 4-6 months duration, is a complete demonstration of independent client service by the student, and is expected to generate a professional design assignment with application and implementation capabilities.

It exposes the student to a real life situation of working in the industry and helps oneself to understand the constraints and limitations of an organization. It involves understanding the strength, infrastructure of the organization, analyze that and give them an appropriate solution within the given extent and time constraint. It also helps to understand the role of a designer, which in practical situation is not only restricted to just design alone, but also includes time management, communicating your idea well and trying to sell your design to those in-charge.

The diploma project helps student to realize his strengths and weaknesses before entering into the professional world of design. I pursued my diploma project for six months from March 2014 to september 2014 at Platypus Design Pvt Ltd,Ahmedabad, India.

Rotomolding Furniture for living room

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Acknowledgments

I would like to thank Platypus Design Pvt Ltd for presenting me an opportunity to work on this concept design project.

It is my pleasure to express my gratitude to Mr Prakash Vani, my project sponsor / guide/mentor (The owner of the company & alumnus of NID) for offering me an opportunity to work on Rotomolding process to create an affordable living room furniture for Indian middle class people.

My special thanks to my guide Mr. Krishnesh Mehta (Faculty Industrial design, NID Ahmedabad), Many thanks to all my faculty members at NID, who have imparted and shared their experience and knowledge to make me a professional.

I express my sincere gratitude towards everyone who made this project possible throughout the process.

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

National institute of design The National Institute of Design (NID) is internationally acclaimed as one of the foremost multidiscplinary Institutions in the field of Design Education and research. The Business Week, USA has listed NID as one of the top 25 European & Asian program’s in the world. The Institute functions as an autonomous body under the Department of Industrial Policy & Promotion, Ministry of Commerce & Industry, Government of India. NID is recognized by the Dept. of Scientific & Industrial research (DSIR) under Ministry of Science & Technology, Government of India, as a scientific and industrial design research organization. NID has been a pioneer in Industrial Design Education after Bauhaus and Ulm in Germany.

NID’s graduates have made a mark in key sectors of commerce, industry and social development by taking the role of catalysts and through thought leadership.

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Content Project abstract Project Introduction Objective Methodology Design process Design Questions

1 2 3 4 4 5

COMPREHEND Material And process study Design Guidelines for rotomolding User survey User interviews User interview Questioner Observation Table User study Insights Activity analysis Zaltmans metaphor elicitation tequnique Market scenario

8-20 10- 20 21 24-42 43 -44 45-49 50-52 53-55 56 -61 62-72

HYPOTHESIZE Hypothesis Redefined brief IDEATE Initial concepts Furniture size analysis Concepts A & C Ergonomic posture study Mechanism concepts Detailing explorations for Hand rest Box Detailing explorations for storage Box Form exploration for Armrest and backrest integrated Form refinement Armrest and backrest integrated Product renderings Bibliography-

76 77-78 80-83 84-85 86 87 88-93 94 95 96 97-99 100-102 103

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Abstract

In India there is a need for intervention in an area of lower and middle income group segment regarding their requirement of furniture for storage spaces and usable living spaces.

So ,an affordable customized furniture with respect to availability of residential space is needed for this segment of society.

Space constraint and multyfunctionality are the major concerns in the typical residences of this segment. Storage has one of the greatest importance in day to day living.Less Availability of carpenters for customized furniture job is responsible for higher customization charges making it unaffordable for this users.

This shows and opens the opportunity for mass manufacturing process to arise with solution either with the end product or a product allowing semicustomization. The plastic molding process called ‘Rotomolding’ was suppose to use for design development .Project started with these guidelines and followed by detailed market study and user study .later the refined brief was built after understanding the market and user’s needs to give design solution.

Rotomolding Furniture for living room

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Introduction In India, among middle class segment Possessing a residence is a key aspiration. While getting the rationally affordable residence is hard due to deception of the developers and dysfunction of Real estate regulatory authority ( RERA).

Consumer already struggling with escalating home loan rates and unaffordable houses so it is hardly able to dream a comfortable life inside house.

Available commodities are neither satisfactory nor helpful to accustom their lifestyle. So user ends up compromising while dealing with product. This shows there is a scope to intervene the new design ideas to this segment and make it easier for them to look for an appropriate alternative.......... ‘ By studying their living environment in a typical residence & taking into account an affordability, availability of a space, their day today activities.

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Objective

To provide a ‘Comfortable living’ for ‘Enforced Urban lifestyle’ of an ‘Indian middle class segment’ with improved quality of life which fits their aspirations, dreams and budget.

Design briefTo design an afordable,multifunctional- residential furniture for middle income group people of India. (perticularly in metros like Pune,Ahmedabad,Mumbai) With the guidelines of mass manufacturing process of Rotomolding the fastest growing plastics processing methods.

By identifying the must residential need. So brief was open to design any seating/sleeping/storing/stacking furniture.

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Methodology The design process

COMPREHEND

HYPOTHESIZE

IDEATE

The design activities covered under this project are as given here: Comprehend -Market Scenario, User Study, Mechanism Study, Product Study, Material and process study, Insights Hypothesize -Redefined design brief Ideate -Design and development (product,comfortable and personal,costumizable) Prototype - Model making , 3d dwg

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

PROTOTYPE

Design questions 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

What are the needs of user in a residential space specially in living room area?

How user uses his/her residential space?

What is the need in day to day life that should not be overlooked or missed?

What type of furniture they use in a small space?

What are the flaws in current market furniture especially in sofas and beds ?Is user using such product?

How do they deal with the current market product/furniture?

Do they use customised furniture?

What is the market scenario of sofa cum beds?

Is any additional feature provided in case of sofas in terms of storage?

What are the issues faced by the users while using the furniture?

What are the materials used in these furniture?

Why are they used?

How rotomolding will satisfy the need?

What are the design elements that would make a sofa unique?

How the traditional sofas are made? What are the drawbacks in terms of production process?

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Comprehend

Material And Process Study

Design and fill

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

heat & spin

cool & open

Rotational molding Rotational molding – also referred to as rotomolding or rotational casting - is one of the fastest growing plastics processing methods today.

It can be used to make hollow items of any size, open or closed, and of any desired shape.

In recent years, rotomolding techniques have been developed extensively. On the production line,this process can now compete with or outperform blow molding,injection molding and thermoforming.

In many cases, pieces virtually impossible to fabricate by any other processes can be produced by rotomolding.

Within a few years, the development-of low and high density polyethylene specifically designed for rotomolding enabled rotational molders to enter markets where vinyl parts and processes could not compete.

In the early 1970s, cross linkable and modified polyethylene grades made their way into the rotational molding market. These new resins again opened up more new market areas, especially production of large tanks.

Linear low density polyethylene for rotomolding was developed in the late 1970s, while the 1980s brought a surge of non-polyethylene resins, including nylon, polypropylene and polycarbonate for rotomolding.

Basics of the Rotational Moulding Process Loading: The exact amount of powdered plastic, equal in weight to the moulded product; is placed in the bottom section of a split mould.

Heating: The tool halves are closed by clamping together. Heat is applied at a controlled rate whilst the mould is rotated slowly about two axes at right angles to each other.

Because the tool is rotated slowly no centrifugal force {which would throw material outwards} is involved. The powered plastic material remains in the bottom portion of the tool.

As the tool rotates; all the surfaces of the cavity eventually pass under the bulk of powdered plastic material. When the temperature on the inside surface of the tool becomes high enough, the plastic adheres to the inside walls as a thin layer.

As the tool continues to rotate, it will pass under the powdered plastic again & again, until all the plastic material has been layered onto the inside surface of the tool .Once all of the material has been layered, on the tool walls, the heating is continued to allow a} all the particles to melt and flow out to give a smooth inside surface to the part,and b} the air bubbles, initially trapped in the plastic wall, dissolve and give a completely solid void free moulding wall. When this has been achieved the tool is the cooled.

Cooling: The tool is transferred to the cooling station where is it subjected to air, water jets or water mist cooling. The tool cools down and the part solidifies retaining the shape.

Unloading: After cooling, the tool is transferred to the unloading station where the two halves are opened up and the product is then removed. The tool can then be recharged with powder and the process will begin again.

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Design

Design guidelines

During the design stage is important to consider all the details of the rotational moulding process. Some fundamental guidelines for the design are: • avoid very large flat surfaces. The parts manufactured with this process are free to shrink while cooling: flat surfaces tend to curve.

• specify a nominal thickness value with an indication of minimum thickness allowed: typically variations may be around ± 20%, except in particular areas (flanges, stiffening ribs, vents, deep cores etc) where the variation may be much greater.

• check that the material required can be contained in the cavity, and if necessary consider the use of a Drop Box. • Design deep cores and pockets so as to have a good heat flow. If thicker walls are required consider the use of air flow amplifiers (air movers - Venturi tubes).

• When designing, take into account the material heat expansion coefficient.

• keep zones that could be subjected to stress away from the parting line • arrange the inserts to allow a good filling.

• remember that the material softening point of polyethylene is low (65°C – 150F). Parts that require higher values must be moulded in polyamide or polypropylene.

At the end of the design, the result will be a set of 2D and 3D drawings, so that the customer and the moulder can see the component to be produced and analyse the part and its function.

The drawings need to highlight all the details needed by the moulder and tool maker to build a good quality mould (tolerances, radiuses, surface finishing, etc.).

Rotational moulding offers a great deal of freedom in design and has fewer restrictions than other processes used for the manufacture of plastic parts. It can be used to produce open or closed items with dimensions that can start from diameters as small as 25-50 mm. The shapes can be simple (spheres, containers) or complex (fuel tanks, automotive components).

Parts can be moulded with thicknesses starting from 1.0 mm up to 50mm.The parts may be coloured or transparent, flexible or rigid.

The decision to use the rotational mould process depends on:

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

1. Number of parts Rotational moulding is suitable for small production runs, but it can be used for the production of 50,000 – 100,000 parts/year. Above these values a more automated process should be considered. However, in cases where the rotational moulding is the only viable process, higher production outputs can be obtained using multiple moulds and machines.

2. Shapes complexity The complexity of the shapes that can be obtained with rotational moulding is almost endless. Fuel tanks are an example of how traditional parts that require several production stages can be obtained in a single moulding operation. This means not only a reduction in costs but also a better design.

3. Dimensions Generally large size products are produced by rotational moulding, even if the possibilities are increasing for injection moulding and blow moulding to produce parts with increasingly large dimensions and wall thicknesses. With the rotational moulding process tanks can be produced with a capacity up to 75,000 litres.

Parts having the dimensions of a can collection bin are at present manufactured by injection moulding and blow moulding if the production throughput justifies the large investment in equipment. For small quantities rotational moulding is almost always the logical choice (the investment & set up costs are lower compared to other processes).

4. Materials Rotational moulding usually uses low cost materials (PE, PA, PP, PVC).

The material specifications are governed by precise requirements: rigid/flexibile properties required by the part (surface properties), working temperature, colour and UV requirements.

The use of materials other than those mentioned above requires a much more accurate process control.

Wall thikness The ideal way to specify the wall thickness on a rotationally moulded part is to specify the NOMINAL wall thickness and also the MINIMUM wall thickness that can be allowed anywhere on the part. Since moulding is done with a female tool only – with no matching male portion of the tool – accurate wall thickness is not attainable.

A tolerance of +-20% should be considered as a commercial tolerance whereas +-10% would be precision and be more expensive to maintain.

Usually the moulded parts have a thickness that varies between 2mm and 15mm. Thinner parts have been moulded (for example 0.5mm for aerospace applications) and also thicker parts (for example large tanks with thicknesses over 30mm), but they require special processing cycles and controls.

The tolerance is usually valid for articles: • with bending radiuses at least 6 times the wall thickness Fig. 5.10 – Bending radius • away from flanges, inserts, kiss – offs (see paragraph 5.2.8) • away from deep cavities and zones where access for the powder is impeded.

It should also be noted that because of material flow characteristics outside corners tend to be thicker that nominal wall {usually an advantage since outside corners are frequently heavily loaded} whereas projections into the moulding tend to thin out. These are generally not regarded within the general wall tolerance.

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Draft angle With rotational moulding it is possible to produce articles without the need for draft angles since the material, as it cools, shrinks and detaches from the mould. However it is always better to have a geometry that helps in the removal of the component from the mould.

For large hollow parts, the draft angle on the external surface may not be necessary, but it is always advisable to put even only 1° of draft angle (assuming this does not influence the product function).

The draft angle also depends on the material used.

Materials with a high shrinkage value (crystalline) such as PE and PA can be removed from the mould cavity more easily in comparison to materials with a low shrinkage (amorphous) like PVC. Materials that are more rigid than PE (like PC and PA) usually require a greater draft angle to ensure removal from the mould.

Article external surface

surface that during shrinkage tends to come away and separate from the mould

Article internal surface

surface that during shrinkage tends to approach,making it difficult to detach the part from the mould

Direction of manufact wall motion during shrinkage

The recommended draft angles are indicated in table

Material

Manufact EXTERNAL surfaces = free shrinkage zones* Manufact INTERNAL surfaces = zone with restricted shrinage** Minimum draft angle

recomended draft angle

Minimum draft angle

0°

1°

1°

2°

PVC

0°

1.5°

1°

3°

PA

1°

1.5°

1.5°

3°

1.5°

2°

2°

4°

Polycarbonate

* These are areas where the shrinkage creates release and separation of the part from the mould ** These are zones where the shrinkage pushes the part against the mould (recesses, through holes, internal stiffening ribs, etc)

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recomended draft angle

Polyethylene

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Radius and angles The ideal shape of a rotational moulding is a sphere, therefore the importance of the radiuses should be easily understood.

Rounding off corner allows the powder to flow more easily creating an even distribution of the thicknesses. The corners are the place where stress concetrations take place, and it may be difficult to fill them.

A recommended standard radius for polyethylene is:

There are two particular situations that require larger radiuses:

• 5 mm for external angles (in any case always R>2 times the wall thickness) • 10 mm for internal angles (R>4 times the wall thickness).

More rigid materials, like polyamide and polycarbonate, require wider radiuses.

Radiuses are recommended with values over: • 10 mm for external angles • 20 mm for internal angles

• when the thickness of the part is more than 5mm it is necessary to: − increase the radius of the external corners to have a value that is at least twice that of the wall thickness − the radius of the internal corners must be at least 4 times the wall thickness • when there are corners that are less than 45° the radius must be at least 10 mm if external (convex zone) and 20 mm if internal (concave zone).

RAdiuses for internal angles (concav zones) (mm)

RAdiuses for external angles (concav zones) (mm)

ideal

20

10

commercial

10

5

minimum

5

5

ideal

10

3

commercial

6

2

minimum

3

10

ideal

20

10

commercial

10

10

minimum

5

5

ideal

20

10

commercial

12

6

minimum

6

3

Material

The internal angles tend to have less thickness as the time in contact with the material is less: it is for this reason that radius on internal corners have to be greater in relation to those of external corners.

Large radiuses improve the flow of the material inside the mould and help to distribute the stress over a wider area, increasing the strength of the part.

In the external corners there is a greater material thickness. This can be useful in zones where stress and wear are greater.

Polyethylene

PVC

PA

Polycarbonate

Mould radiuses recommended for the various materials used in rotational moulding

LAND HO! seat,– designer El Ultimo Grito

BUCKY II seat, designer Marc Newson

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Reinforcement The materials used in rotational moulding usually have a low modulus of elasticity: to increase the stiffness of the articles moulded with this manufacturing process it is important to design so as to exploit the geometry and the shape.

In a part subjected to tensile stress, the resistance is linearly dependent on its thickness,whereas for a part subject to deflection stress the resistance is in proportion to the cube of the thickness.

SANTAMONICA chair, designer Denis Santachiara

There are basically two ways to increase the strength of a part,: • increase the quantity of plastic material (therefore thicknesses and costs) • use stiffening ribs for reinforcement, that increase the stiffness of the part whilst still keeping an even wall thickness.

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Stiffening ribs are used for reinforcement, and increase the stiffness without increasing the part wall thickness.

HEROS stool, designer Cristian Gori

Stiffening ribs used in the mineral water bottles is a clear example of there effectiveness.

Bottle geometry with and without stiffening ribs.

Radius and angles In rotational moulding ribs with fins cannot be used as the way they are used in injection moulding to stiffen thin surface areas. The powder would be unable to enter into the deep cavities ofthe mould and the resultant stiffening would be poor.

There are two types of ribs: 1. double wall rib Allows the material to cover the internal surface of the mould easily. They have to be designed so that: WIDTH≥HEIGHT HEIGHT ≥ 4S

The single wall ribs can also be used for other purposes: • they can give an additional thickness to surfaces subject to abrasion on the bottom of tanks. In this way the life cycle of the part is extended.

• they can be used to create a connection between two parts.Generally, the use of a number of narrower and shorter stiffening ribs can be more advantageous than using a single wide one.

During the design phase it is necessary to consider the stress that the part will be subjected to during its service life.

Ribs for injection moulding Usually corrugated sections are designed into the areas where stiffening is needed in a rotationally moulded part.

2.single wall rib The maximum height is: HEIGHT ≤ 3s as filling problems arise during moulding. Furthermore, the extra thickness that occurs at the base of the rib produces greater shrinkage, more distortion and longer cooling times.

These solutions are not good

Ribs for rotational moulding Ribs recessed (introverted) in the part

Ribs in rotational moulding

To reinforce parts, recessed stiffening ribs can be used, following the same rules as for those in positive. They can be used as decoration to break up wide flat surfaces.

The ribs increase the rigidity if the load is at 90° to the corrugation.

Containers for the selective collection of solid urban waste ECOBELL2500 (by courtesy of Sinterplast SpA)

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Holes These can be created in several ways, using: • Through pins

To improve the heat transfer the core must be produced with half on one section of the mould and half on the other section. Where ever possible a hole should be included inside • Knife edge mould part

• Insulation panels These are used to thermally insulate areas of the mould and create colder areas where the material does not adhere to the surface of the mould. To obtain this, a sheet of PTFE (Teflon) or a mineral wool layer is usually used. They are designed smaller than the required hole since the immediately surrounding area will have a thinner wall (which will be removed).

Further finishing operations are necessary.

Bosses

Bosses may have different uses: • as reinforcement • as pins for parts that are assembled to allow for rotation • as separators/spacers between different parts.

Multi-purpose objects HOLE (Chair – small table), designer Yuko Tsurumaru

• Cores

Care must be taken to provide the necessary draft angles and an adequate heat transfer.

Since the part shrinks around the core, at least 3° are necessary to be able to remove it, 5° would be even better.

Fig. Hole obtained by the use of cores on the mould

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

The height of the boss should be: h<d The end of the boss can be cut and removed to create a hole.

This gives more flexibility in the design of tanks and containers.

Possible shapes for bosses

Undercuts

KIss offs These are features that join two opposite walls, over a limited area. They can increase the strength of the part and can be used in series or separately.

There are two types:

A Kiss-off B Partial kiss - off

To solve this problem it is possible to use “partial kissoffs” (or support ribs), leaving a minimum space between the two walls.

A good start-off could be to produce a kiss-off with height hB equal to: hB ≥ 2s With a space Sc (fig. 5.36) between the tip of it and the opposite surface so that Sc ≥ 3 mm Since the kiss-off is no longer a connecting element between the two surfaces, there will not be any unattractive surface marks.

Undercuts are internal or external protrusions that can impede the removal of the part from the mold.

Compared to other plastic material manufacturing processes, rotational moulding is less restricted by the presence of undercuts.This is because the moulded material is free to shrink away from to the internal surface of the mould during cooling: it could happen that the part shrinkage is equal to or more than the size of the undercut.

Mould parting line

hA = depth of 1st stiffening rib hB = depth of 2nd stiffening ribt The mould separation gap where the kiss-off faces to the opposite wall has to be: thickness SA in point A = 1.5 ÷1.75 s.

It is better to start with height SA less than the requirements, increasing the gap if necessary with subsequent removal of material from the mould.

The values suggested above are to be decreased for kiss-offs in locations with low thickness zones, up to: SA = 1 ÷ 1.25 s There must be sufficient space between one kiss-off and another to allow the material to flow through the cavity around these features:

A disadvantage is that they can create marks on the surface where they join. This may not be acceptable for parts where appearance is important.

Example of positive undercut (everted profile) Usually, for articles in polyethylene, positive everted undercuts with dimensions that may reach up to 50% of the expected linear shrinkage are considered acceptable.

For flexible materials like PVC, larger undercut dimensions can be considered (for example,dolls heads are extracted from the neck zone).

More rigid materials, such as PA and PC, have less flexibility and therefore less tolerance to undercuts.

Undercuts on cores must be avoided, as the material shrinks onto the core tightening around it.

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In some cases protruding undercuts can be accepted if the part can be twisted in order to extract it from half of the mould.

The rotational moulding of this lamp takes place with the aid of movable blocks inserted in the mould. This allows the extraction of the part and avoids problems caused by undercuts.

Hanging lamp STARLIGHT, designer Tom Dixon

Threads External and internal threads can be produced.

External threads should not to be positioned along the parting line of the mould.

Internal threads require additional mould section or cores that have to be unscrewed before removing the part from the mould.

Small, narrow threads can be obtained by the use of metal inserts which are introduced into the mould. During the heating/moulding process these are covered by the polymer. In the case of plastic inserts, they become joined onto part during the moulding process.

Threads can be obtained: • Directly in the moulding: produced by a movable section inserted in the mould that reproduces the shape of the thread and the related dimensions. To obtain a part without faults, the following recommendations are to be followed at the time of the designing the product: − pitch more than 4 mm − threaded section with rounded shape

Type of recommended threads

The thread is a restriction to shrinkage (shrinkage causes tensions).

The higher the fluidity of the material (M.F.I.) the better the surface appearance of the thread will be.

• by post moulding operations: − pitch less than 4 mm − higher costs The production of threads by post moulding mechanical machining on the part usually produces threads with jagged edges and a poor quality surface finish.

The higher the fluidity of the material (M.F.I.) the better the surface appearance of the thread will be.

• by post moulding operations: − pitch less than 4 mm − higher costs The production of threads by post moulding mechanical machining on the part usually produces threads with jagged edges and a poor quality surface finish.

Inserts

Resistance to shrinkage caused by a thread

Where threads are produced directly by moulding the tensions could be so high that distortion could occur, causing tapered walls.

An advantage of the rotational moulding process is the ease with which metal inserts or plastic inserts can be moulded together with the component.

The insert must be produced: • with a material with a high thermal conductivity

Low thermal conductivity

Recommended geometry for threads

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Tapered walls in threaded zone Taper: angle α = max 2°- 3°

Good thermal conductivity

Distribution of polymer thickness according to thermal conductivity of the insert

with a geometry which ensures a good anchorage (torsional and axial strength).

The insert torsion resistance is important, because many inserts are used in the assembly of parts composed of several items.

The inserts are not to be placed too near to edges because they could decrease the material flow in that areat.

Torsional strength Poor axial strenght

Good axial strenght

Axial strength (withdrawal-resistance) depending upon the shape of the insert

The most common types are: • In brass: good chemical resistance, strong thread, expensive • In stainless steel: corrosion-proof, expensive •In aluminium: economical, good conductivity, weak thread • In steel: excellent thread integrity, corrosion risks During the moulding process the plastic (polymer) powder sticks on the metal insert (when hot enough) covering and incorporating it into the moulded part. To ensure good adhesion the insert has to be clean and free from oil and dirt.

The inserts are positioned on the mould and fixed in place during the moulding process by screws and bolts, springs or magnets. If springs are used the insert will have the freedom to move with the shrinkage of the part: this may reduce or eliminate the any distortion associated with the fastening of the insert.

The positioning of the inserts could influence the warpage because the insert acts as a restraint to the shrinkage.

Inserts restraint to shrinkage

Since the adhesion between the metal insert and the polymer is purely mechanical, a hermetic seal cannot be guaranteed on inserts with through hole, especially where there are pressure and temperature variations.

The hydraulic seal is ensured by the use of special gaskets that operate in direct contact with the polymer.

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Distortion and flatness considerations Wide flat surfaces are usually difficult to produce in all plastic moulding processes. In rotational moulding the difficulty is higher because the polymer is only bonded on the external part (to the mould). Therefore, it is usual experience that in flat zones warpage often takes place: a wide concave or convex deformation of the part walls.

F is defined as the maximum deflection from the nominal shape of the part, the ratio F/X (where X is the length of the part) is used as the sagging dimension index.

Depending upon the level of surface flatness required, three tolerance classes are defined for the deflection value F, as % of X

The problem is highly evident in crystalline materials such as polyethylene. Therefore, where ever possible, it is advisable to break up these surfaces with stiffening ribs, profile sections, decorative items, etc. Creating steps or cavities on flat surfaces reinforces the moulded surface reducing the degree of distortion and, moreover, reduces the perception of deformations, distracting the eye of the observer.The presence of sharp edges or very small corner radiuses usually increases warpage; this can be controlled by increasing the corner radius. Radiuses less than twice the wall thickness can be critical if the angle is less than 30째.

Bending radius on edge

Metal Inserts

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Smooth or polished surfaces make distortion worse. Deep textures keep the polymer in contact with the wall of the mould and reduce distortion. Textures improve surface appearance even when this is slightly distorted An internal pressure that forces the material to adhere to the surface of the mould while it cools can be used to reduce the level of distortion.

Rotomolding products by great designers

The Magic Hole armchair by Philippe Starck

Thomas heather-wick Spun chair

Driade MT1 Chair by Ron Arad

Rotomolding Furniture for living room

Possibilities in Rotomolding

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

User Study

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Need of user study

Ahmedabad Mumbai Pune

It was important to understand the users lifestyle in depth to come up with very practical solution.

Different people use same space,product,furniture differently. Understanding user helps to know more about limitations and considerable aspects while using currently available products in market.

There would be cases when user is exposed to a completely new product category. In such cases, to design new, innovative products; the designer needs to thoroughly understand shortcomings of existing products, user pain points as well as generate a desirable product which would satisfy the userâ&#x20AC;&#x2122;s unmet needs. So, getting to know more about the user, his/her lifestyle, needs and wants, daily routine activities helps in learning about which, where and how to enhance user experiences.

Questions This project needed in-depth understanding of how Indian middle class people use their residential spaces.

How they use living room ? How Do they use furniture in living room and bed room? Do they use sofas? Do they prefer sleeping on sofas in living room?

Do they eat on dinning table or floor? How do they arrange their rooms when guests are there? (in case of 1BHK/2BHK tenement) It was necessary to find which activities were given more importance while using the furniture/product.

Design intervention which would increase convenience by changing the way the user accesses furniture/product.

Rotomolding Furniture for living room

23

24

User interviews

User scenarios

Metaphor elicitation

Interviews can be conducted with a pre-planned set of questions or with an approach of asking questions based on user responses. It is most effective when the conversation is responsive as it helps in capturing the deeper insights.

Stories that represent the how people interact with space,furniture or the issues & limitations faced by them in real world. It represented in form of text or visuals. It helps in getting insights about existing products/services/user interaction and help in improving them.

It is about study of Picture that represents how user think unconsciously while buying a particular product from market.

The goal of the ZMET interviews and analysis is to uncover the relevant fundamental structures that guide peopleâ&#x20AC;&#x2122;s thinking about a topic. These deep structures are unconscious, basic orienting frames of human thought that affect how people process and react to information or a stimulus.

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

User interview As a part of field research users houses i.e.1BHK and 2BHK tenements in Ahmadabad and Pune were studied and user interviews were conducted. Initial visits were conducted to those houses where the monthly family income was from 15,000 to 45,000.

Most of them were staying in one BHK Then user staying in 2BHK tenements were studied where family income was above 45000.

The study of 20 such houses helped me to understand that user has already adopted their own methods of arranging things in a residential space.

A common thing in living room observed was use of â&#x20AC;&#x2DC;Single bed with storageâ&#x20AC;&#x2122; as a seating for guests in day time and as a bed for family members for sleeping in night. Even if a bed has no storage facility user has started using the space underneath for storing cartons filled with stuffs,bags etc.

Storage requirement of these families were more as this segment had 5-9 family members on an average.

Because of their depth single beds available were not comfortable as it had no back support. So in case of long time and relaxed seating requirement it use to fail. Depth would be more than enough for a one person to sleep. These sleeping and seating depths were of no perfect use. As well this single bed use to eat up the maximum space in living-room making it cramped.

Material used for these beds were mostly plywood and metal.

Rotomolding Furniture for living room

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Dinesh Kumar house

Case study no -1

Dinesh kumar works in N.I.D. as a library assistant. He is a government employee. He resides in staff quarters in N.I.D,Paldi ,Ahmadabad. Family includes two children and two adults. All of them prefer to eat on floor and sleep on bed.

Plywood bed with storage Bed is kept in bed room used as sofa as living room size is less.

Space is formal (in day time)as well informal(night time).

Things stored above floor on corner piece

Wardrobe kept in living-room Top of it used to store bag and carton

Space below bed used for storing things.

Wall corners are used as T.V. Unit and display unit.

Storage space provided above bathroom.

Balcony provided with storage of two partition.

Window lintel used for keeping shoes

Insights - Living room has less space available compared to bedroom and it is near to kitchen also. Hence to maintain seclusion from Indian kitchen and to have enough space, formal seating is provided in bedroom which also act as t.v.room. Where Two single beds are also utilized as sofas.

26

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Ravi Limbachiya house

Case study no -2

Ravi Limbachiya who works at Platypus private limited has family of seven people located in Vadaj area of Ahmadabad. Two members of the family are working.

His younger brother runs a private boutique in Vadaj. Raviâ&#x20AC;&#x2122;s mother also helps sometime in their private business of boutique. He has 2BHK house. Family members are more to the space available in house.

Wardrobe is kept in living-room top of it used to store bag and cartons filled with stuff.

Fridge is kept near the wardrobe in living room corner.

T.V. Unit with storage Plastic coffee table and chairs

Bedroom has a be with storage and a study table for adults and kids both.

Wooden coffee table.

Wardrobe is kept in living-room Top of it used to store bag and carton.

Entry to the house starts with kitchen and ends with living room on ground floor. One room upstairs is used as bedroom.

Single bed along with storage underneath. A single bed is kept in living room for elderly people to sleep and for guests to have a seat.

Overlooking kitchen space

But every body in the family prefer to sit on the ground for collective activity like having food or conversation.

Insights - Due to less available space grand parents stays in living-room so,their belongings and wardrobe are placed in living room. There is still a scope for using the corners in improved way . Though there is a bedroom upstairs ,elderly people cant climb down the staircase often because of knee problem.

So Living room space is used as Multi-functional space..

Rotomolding Furniture for living room

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Kiran Solanki house

Case study no -3

Kiran Solanki works as junior technician in metal workshop at National institute of design,Paldi,Ahmadabad. There are total four people in his family.

Three of them are working. He has a 1bhk house in Maninagar , Ahmadabad. Family prefer eating on floor while every body sleeps on bed.

Corner of the room is used for display,storage and for keeping television.

Stackable plasic chairs are used in lliving room.

All family members clothes are kept in a inbuilt wall cupboard.

A small wooden coffee table is used to stack newvs paper and also used as a side table.

Regularly used clothes are hung at this corner of the living room.

Stackable plastic chairs are used when guests are there otherwise they are stacked.

Metal bed with storage is kept in living room which is top loaded.

Living room area in the night transforms into sleeping space. Four beds are arranged in an available space.

Insights - Though there is a bedroom upstaire ,elderly people cant climb down the staircase often because of knee problem.

So living room space is used as multi functional .

28

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Deepak Panchal house

Case study no -4

Deepak Panchal is a senior technician working in N.I.D. since 10 years in a metal workshop. He his family includes two children,two adults and one elderly person. Being technician he has achieved to use every corner of his house skillfully.He himself designed the whole furniture of his house as those are unaffordable in market.

This is a case where one can easily learn the storage requirement and placement.

Living-room is loaded with storage furniture.

Swing a traditional furniture of Gujarat which you can find in varhanda in every house .In modern context Deepak bhai has places it in living room.

Sofa with drawer storage Coffee table of metal,plywood and glass

Computer table used as T.V. unit Small storage cabin-ate with seating provision.

Regularly used things are kept on floor with vertical stacking arrangement.

Folding dinning table in plywood (behind deepak bhai in picture) has solved elderly persons knee problem as well as smart solution for small space.

Insights - Though the storage need of a family is fulfilled other aspects of a furniture like backrest ,hand rest in seating arrangement is needed for body comfert as well necessary for elderly.

Rotomolding Furniture for living room

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Hiral vyas house

Case study no -5

Hiral vyas is a house wife stays in vadaj, ahmedabad in a 1BHK flat.Her family includes two children,two adults. she needed a less maintaned living room furniture with a lot of flexibility such as sofa cum bed,sofa along with storage.

T.V. unit

kids plas-

wooden coffee table swing is used as a seating in living room

randomly arranged sofas sofas are of different type and material

Available space in windows grills are also used due to less storage option available in the form of furniture.

Metal wardrobe in bedroom customised bed with

Insights - Living room has a lot of scope for storing things and seating arrangement .

30

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Regularly used things like blankets, bedspread,quilts are kept on trunk of cereal with vertical stacking arrangement.

Pratik Patel house

Case study no -6

Pratik Patel works as junior technician in Wood workshop at National institute of design. there are total three people in his family.Pratik is the only working person n the family.Its a 1bhk house in badoda highway ,maninagar ,ahmedabad.

Family prefer eating on floor while every body sleeps on floor.

Single bed with carpet kept underneath.

Single bed used as seating for guests.

A niche for display corner T.V. unit

Plastic stackable chairs are used in case of big no of guests are arrived.

Inbult storage used to keep kitchen stuff and clothes. cylinder,cereal trunk is kept in the middle room . Regularly used clothes are hung on the door back.

Metal wardrobes are used to keep clothings Top of wardrobe is used to stack things.

Insights - Inough area for three people.Storage furniture is needed.Every one tries to not store or stack on floor .

Rotomolding Furniture for living room

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Suryaben Jitendra Shin Dahabi

Case study no -7

Suryaben Jitendra Shin Dahabi is wife of maintainance personal who works at national institute of design.

There are total five people in his family. One child, two adults and two elderly person.Her husbund and father in law are the working people form family. She has one bhk staff residence in N.I.D. Staff quarters.Every one from family prefers to sleep on bed and eat on floor.

Lots of her guests comes 3-4 times in a week to meet and 3-4 times in a month to stay for medical treatments as Ahmedabad is the only city near to there village.

Single wooden bed used as seating for

wooden coffee table.

In the night time same space transforms into the bedroom with the char pai

Multipurpose function of living room is a necessary where less space is available.But it is realy time consuming and tiring prosess to trnasform .

Corners of bedroom is uesd to keep tv unit.

So it is also use das tv room.Baby swing is kept in a bedroom.Front wall is used for the display of family pictures and posters.

Elderly people from family use bedroom as there sleeping area .

Floor space is also used for sleeping when guests are there.

Insights - House is filled to its capacity with people.Floor stacking is encouraged only below bed and on top of cupboards.

32

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Upendra patel

Case study no -8

Upendra Patel is graduate in comuter science and works at Computer mantainance depatment in NID.There are total three people in his family,he,his wife and their son.Upendra stays in Two BHK flat which is on rental basis in maninagar of ahmedabad.

Every one from family prefers to sleep on bed and eat on floor.

He would prefer to have one dinning table in future. Generaly guests comes weekly to meet him and his family.he finds enough space for guests.

In case of their stay metal charpai is used for sleeping.

study table for adults study table for a kid Stackable plastic chairs are used in living room

wooden coffee table.

Wooden single bed for seating in living room used for .

Stackable plastic chairs are used in bedroom as well

cereal storage trunks are kept in the same bedroom near to the kitchen.

Blankets ,rugs,quilts are stack on the trunks.

Metal charpai used at the night time otherwise stacked along the wall vertically in one of the bedroom.

top of cupboard used for stacking.

Insights -Enough space for three people.Storage furniture is needed.Seating arrangements are not enough in house.

Rotomolding Furniture for living room

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Indira shalgar

Case study no 9

Indira shalgar works as xerox machine operator in NID. She is 40 year old.She lives in maninagar ,Ahmedabad.In her family there are two elderly person,three children,and four adults.

She has 1 BHK in maninagar area.Family mambers are more to the spac eavailable in house.

Everybody from family prefer to sleep on floor and eat on floor.

Family uses stackable plasic chair in lliving room.

Metal wardrobe is used by elderly people which is kept in living room.

Wall mounted T.V. unit and speakers wall mounted display unit to showcase family memories

Baby swing kept in living room living room used ad study area by kids

A big storage facade in bedroom with open and closed storage stack

Insights - Due to less available space grand parents stays in living-room so,their belongings and wardrobe are placed in living room. There is still a scope for using the corners in improved way . So Living room space is used as Multi-functional space..

34

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Indrajit Singh Wagela

Case study no 10

Indrajit Singh Wagela works as security personal at National Institute of Design. There are total four people in his family. Two children and two adults is the only family. He has one B.H.K. Staff residence in N.I.D. Staff quarters at Paldi ,Ahmadabad. Every one from family prefers to sleeps on bed and eat on floor. Indrajit is the only working person in their family. Lots of his guests comes 3-4 times in a week to meet him and 3-4 times in a month to stay for medical treatments as Ahmadabad is the only city near to there village.

Metal wardrobe in living room.

Regularly used clothes are hung on wall

Single bed -with out storage in living room.

Storing bellow bed is not preferred.

wall corners are used as T.V. unit and display unit.

In bedroom two single wooden beds are used due to lack of space.

balcony provided with storage of two partions where heavy things are kept below and light are kept up.

Insights - Living room has less space available compared to bedroom and it is near to kitchen also.hence to maintain seclusion from indian kitchen and to have enough space, formal seating is provided in bedroom which also act as t.v.room.

Rotomolding Furniture for living room

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Jyoti Gajjar house

Case study no 11

Jyoti Gajjar is a house wife. There are total two people in her family including she and her husband who is civil engineer. Her House is in Maninagar area in Ahmadabad.

Guests come on weekly basis. Just to meet them but hardly they make a stay.

Custom made Sofa cum Bed along with the storage .

Sofa used as seating in day time for guests and as bed for two.

Hand rest is not provided.

Wooden Coffee table and stools in living room Inbuilt T.V. unit in wall

Regularly used clothes stacked above floor on small table

Inbuilt Wall shelf for keeping clothes even separate wardrobes are in use.

Stackable plastic chairs are used when more guest are there.

Stacking of things on top of metal wardrobe is seen the wardrobe.

Insights - Living room has sofa which can transform into bed by shifting and aligning two single beds. They are also provided with the storage.

Coffee table and stools are used as dining furniture due to knee joint problems and lack of space to have dining table.

Compare to number of people staying in house storage requirment is more

36

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Sandesha Ghumatkar

Case study no 12

Sandesha Ghumat kar is a working women.She works as a nurse in K.E.M. Hospital, Pune. There are total four people in her family including she and her husband who runs a small printing bussiness and two daughters.Her house is in Pimpalegurav area,Pune. After interacting it is confirmed that guests come on weekly basis. Just to meet them but hardly they make a stay.

T.V. is kept on small wooden coffee table.

Sofa cum double bed is used in living room

old office chair Closed Shelf is is kept in living kept in living room room for kids.

A metal cupboard is kept in bedroom.

wooden shelf used to keep small stuff in bedroom

Insights - Living room has sofa cum bed which hardly get operated. Because size of bed sofa opens into covers almost all the spacein living room and make it cramped.

Rotomolding Furniture for living room

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Gunvant Patidar

Case study no 13

He is a software engineer works in IT company at hinjewadi,Pune. There are only two members in his family he and his wife. Its a one BHK flat and they have minimum but required furniture. Guests comes on weekly holidays not to stay but for get-together.

Both of them prefer to eat on floor but donâ&#x20AC;&#x2122;t mind to have one dining table.

Entrance of the house.

single bed used as sofa in living room.

T.V. kept on computer table

Plastic stackable chair

Queen size metal bed with storage in bed

Inbuilt T.V. unit in wall

Insights - Living room has single metal bed used as sofa in day time and bed for guest in night time. Stackable chairs are been used in living room for guests.

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Revan Khurpe

Case study no 14

He is a software engineer works in IT company at Hinjewadi,Pune. There are only two members in his family he and his wife. Its a rental one BHK flat. Their parents come weekly to meet them and make stay once in a month. Both of them prefer to eat on floor but donâ&#x20AC;&#x2122;t mind to have one dining table.

Glass coffee table

Plastic stackable chair.

Cotton mattress on floor

Double bed with storage

Insights - Stackable plastic chairs and a mattress are the temporary substitute for seating arrangement in living room.

Rotomolding Furniture for living room

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Narmada Parmar

Case study no 15

She is a house wife staying with her husband in Dharnidar derasar area in Ahmadabad.

There are only two members in his family .They have one BHK flat which is well furnished.

Guests comes on weekly holidays not to stay but for get-together. Both of them prefer to eat on table. Sofa which they are using is custom-made and18 years old.

Over the time springs in sofa have become loose not giving the proper cushioning effect.

Corner remains unused /uncomfortable to seat.

Custom made sofa is fulfilling the basic need of seating for five people.

Insights - Living room has custom made sofa.Housewife needs a sofa cum double bed in living room for guests. Stackable chairs are used in living room for guests.

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Dhaval Shah

Case study no 16

He is mechanical engineer works in Ahmadabad . There are five people in his family . Its a two BHK flat and they have minimum but required furniture. Both of their parents comes weekly to stay.

Single bed used as sofa in living room.

Corner remains unused /uncomfortable to seat.

Stackable plastic chairs.

Insights - Living room has two single wooden beds. Which are used as sofa in day time and bed for guest in night time. Stackable chairs are used in living room for guests.

Abhishek Raval

Case study no 17

He works in Vodaphone company at Ahmedabad. There are four members in his family he ,his wife,Mother and father. Its a two BHK flat and they have minimum but required furniture. Guests comes on weekly holidays not to stay but for get-together. All of them prefer to eat on table

Wooden sofa (8 years old )is being used in living room,Cushion is repaired.

In these years.

Single bed used as sofa in living room.

Mohini Rathod

Case study no 18

She is the only working person of the family. There are three members in her family she and her two children. Its a one BHK flat and they have minimum but required furniture. Guests comes on weekly holidays not to stay but for get-together. All of them prefer to eat on floor but donâ&#x20AC;&#x2122;t mind to have one dining table.

Single bed used as sofa in living room.

Stackable plastic chair.

Insights - Living room has wooden sofa which they are using since eight years. Storage requirement has been increased over the period so family need storable furniture which willl suite living room.

Insights - Living room has two single wooden beds with storage.

Which are used as sofa in day time and bed for guests/family member in night time. Stackable chairs are one of seating preferences .

Rotomolding Furniture for living room

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Harish k Satade

Case study no 19

He works in Bank of India in Ahmadabad. There are three members in his family,he, his wife and his daughter. Its a one BHK flat and they have minimum but required furniture. Guests comes on weekly holidays not to stay but for get-together.

Sharmishtha Bharadwaj

Case study no 20

She is a housewife and her husband is an engineer works in IT company at hinjewadi,Pune. There are only four members in his family he and his wife.

Its a one BHK flat and they have minimum but required furniture. Guests comes on weekly holidays not to stay but for get-together. Both of them prefer to eat on floor but donâ&#x20AC;&#x2122;t mind to have one dining table.

3+2 seater sofa

single bed used as sofa in living room.

Insights - Living room has sofa and single bed. Single bed is kept for guests to sleep.

In case of more guests floor space is used for sleeping

42

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

three seater sofa

three seater sofa

Insights - Living room has Two 3+2 sofas .They are custom-made and it is 6 year old. Life of spring is expired and sofa has loosed its cushioning effects. storage furniture is required in living room.

Questionnaire for target user

Name

Age 20-25

26-30

Gender: male

31-40

41-45

female

How many members are there in your family?

No of kids

no of adults

no of elderly

How many people from your family are working?

1

2

3

4

all

What is their qualification?

Metric

Graduate

Post graduate

What is occupation?

Businessman

shopkeeper

private company employee

government employee

Familyâ&#x20AC;&#x2122;s monthly income 20,000

40,000

60,000

More than that

1

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How many bedrooms do you have?

Where do you like/prefer to eat?

0

on floor

1

2

What is the average size of bedrooms?

100sqft

125sqft

12’x9’

13’x9.6’

on table

Would you prefer to have a dining table?

160sqft

200sqft

14’x12’

Yes

no

16’x13’ Where do you sleep?

What is the size of living room?

160sqft

200sqft

250sqft

300sqft

14’x12’

16’x13

17’x15’

19’x16’

Bed

Floor

How do you manage when there is no specific furniture piece for storage?

Where do you spend maximum time when you are home?

Living room

bedroom

Store on the horizontal surfaces

Stack on top of other

Stack above floor

Store on the loft

What is the type of house?

Own

on rent

What pieces of furniture do you have at home?

Living area -

Sofa

coffee table

Dining area- dining table Bedroom

-

bed

side table

TV unit

shoe rack

crockery display unit side table

study table

dressing table

How often guest come to your house?

Weekly

twice in a week

thrice in a week

never

2

44

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

3

Stack on floor

Navneet mistry

Deepakkumar Prajapati

Devendra Solanki

Age

20-25

26-30

31-40

Total Members in family

6

7

3

Working members

2

3

1

Qualification

Metric

metric

Metric

Family â&#x20AC;&#x2DC;s Monthly income

15000-25000

15000-25000

15000-25000

No of bedrooms

2

3

1

Average size of bedroom

160sqft

160sqft

100sqft

Size of living room

160sqft

200sqft

160sqft

Space used for maximum time

Bed room

Living room

Living room

Type of house

Own

Own

Own

Guest arriving frequency

Weekly

Weekly

Weekly

furniture pieces

T.V Unit, 2-single bed, 1-double bed, coffee table, study table, wardrobe.

1- bed with storage, Plastic stackable chair, Coffee table, metal wardrobe.

coffee table, 1double bed with storage, wardrobe

Eating preference

On floor

On floor

On floor

Preference to have dinning table

No

No

Yes

Preference for sleeping on bed /floor

Bed

Bed

Bed

Preference for storing things without a furniture piece

above floor, stacking on top of other

above floor, stacking on top of other

Loft storage, stacking on top of other

Rotomolding Furniture for living room

45

46

Dhaval Shah

Sharmishtha Bharadwaj

Narmada Parmar

Harish k Satade

Abhishek Raval

Age

30-35

26-30

31-40

45-50

25-30

Total Members in family

5

4

3

4

4

Working members

2

1

1

3

3

Qualification

Post graduate

Graduate

Metric

Graduate

Graduate

Family â&#x20AC;&#x2DC;s Monthly income

90000-1,25000

1,00,000-1,25,000

15000-25000

80000-90000

50000-70000

No of bedrooms

2

2

2

1

2

Average size of bedroom

160sqft

160sqft

100sqft

160sqft

160sqft

Size of living room

220sqft

200sqft

160sqft

200sqft

200sqft

Space used for maximum time

Living room

Living room

Living room

Living room

Living room

Type of house

Own

Own

Own

Own

Rent

Guest arriving frequency

Weekly

Weekly

Weekly

Weekly

Weekly

furniture pieces

T.V Unit, 2-single bed, 1-double bed, coffee table, study table, wardrobe.

T.V Unit, sofa, 1double bed, diningtable, coffee table, study table, wardrobe.

coffee table, 1double bed with storage, wardrobe

T.V Unit, 1-single bed, 1-double bed, coffee table, study table, wardrobe.

T.V Unit, 1-single bed, 1-double bed, coffee table, study table, wardrobe

Eating preference

On floor

On Table

On table

On floor

On Table

Preference to have dinning table

No

Yes

Yes

No

Yes

Preference for sleeping on bed /floor

Bed

Bed

Bed

Bed

Bed

Preference for storing things without a furniture piece

Loft, above floor, stacking on top of other

Loft,above floor, stacking on top of other

Loft storage, stacking on top of other

Loft storage, stacking on top of other

Loft storage, stacking on top of other

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Indira Shalgar

Hiral vyas

Indrajit Wagela

Pratik Patel

Surya Dahabi

Age

30+

30+

30+

25+

20+

Total Members in family

9

3

4

3

5

Working members

3

1

1

1

2

Qualification

Metric

Graduate

Graduate

Metric

Graduate

Monthly income

15000-25000

25000-35000

15000-25000

15000-25000

15000-25000

No of bedrooms

1

1

1

1

1

Average size of bedroom

100sqft

125sqft

100sqft

160sqft

125sqft

Size of living room

100sqft

160sqft

160sqft

160sqft

100sqft

Space used for maximum time

Living room

Living room

Living room

Bed room

Living room

Type of house

Own

Own

Rent

Own

Rent

Guest arriving frequency

Weekly

Weekly

Weekly

Weekly

Weekly

furniture pieces

1-Single bed with storage, lots of cupboards, stackable plastic chairs.

Sofa, coffee table, t.V.unit, shoe rack, 1-double bed with storage, metal wardrobe

3-Single bed, coffee table, t.V.unit, shoe rack, metal wardrobe

1-Single bed, t.V.unit, metal wardrobe

3-Single bed, 1charpai,coffee table, t.V.unit, shoe rack, metal wardrobe

Eating preference

On floor

On floor

On floor

On floor

On floor

Preference to have dinning table

Yes

No

No

No

No

Preference for sleeping on bed /floor

Floor

Bed

Bed

Bed

Bed

Preference for storing things without a furniture piece

Loft storage, stacking on top of other

Stack on floor ,stack on loft

Balcony Loft storage, stacking on top of other

Loft storage, stacking above floor

Under bed, top of cupboard

Rotomolding Furniture for living room

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48

Jyoti Gajjar

Revan Khurpe

Moreshwar Ghumat kar

Gunvant Patidar

Sunil Khetmar

Age

41-45

31-40

31-40

26-30

45-50

Total Members in family

2

2

4

2

4

Working members

1

1

1

1

1

Qualification

Graduate

Graduate

Graduate

Graduation

Graduate

Family â&#x20AC;&#x2DC;s Monthly income

35000-45000

<45000

15000-25000

35000-45000

35000-45000

No of bedrooms

1

1

1

1

2

Average size of bedroom

100sqft

100sqft

160sqft

125sqft

100sqft

Size of living room

100sqft

200sqft

160sqft

160sqft

250sqft

Space used for maximum time

Living room

Living room

Living room

Living room

Living room

Type of house

Own

Rent

Own

Own

Rent

Guest arriving frequency

Weekly

Weekly

Weekly

Weekly

Weekly

furniture pieces

Sofa cum bed with storage. coffeetable, TV unit Inbuilt in wall

stackable plastic chairs , 1-double bed with storage, coffee table, wardrobe. shoe rack

Sofa cum bed, T.V.unit, shoe rack, wardrobe.

1-Single bed,1double bed with storage, study table

Table, study table for kids, 1single bed,2charpai, coffeetable, wardrobe,TV unit

Eating preference

On table

On floor

On floor

On floor

On floor

Preference to have dinning table

Yes

No

No

No

Yes

Preference for sleeping on bed /floor

Bed

Bed

floor

Floor

Bed

Preference for storing things without a furniture piece

Stack above floor, stack on top of other

Loft storage, stacking on top of other

Loft storage, top of wardrobe/cupb oard.

Loft storage

Loft storage

Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Ravi Limbachiya

Kiran Solanki

Deepak Panchal

Dinesh Kumar

Upedra Patel

Age

30+

25+

30+

30+

30+

Total Members in family

7

4

5

4

3

Working members

2

3

1

1

1

Qualification

Graduate

Graduate

Metric

Metric

Graduate

Family â&#x20AC;&#x2DC;s Monthly income

25000-35000

25000-35000

15000-25000

15000-25000

35000-45000

No of bedrooms

2

1

1

1

2

Average size of bedroom

100sqft

125sqft

100sqft

125sqft

100sqft

Size of living room

160sqft

160sqft

160sqft

100sqft

250sqft

Space used for maximum time

Living room

Living room

Living room

Living room

Living room

Type of house

Own

Own

Own

Rent

Rent

Guest arriving frequency

Weekly

Weekly

Weekly

Weekly

Weekly

furniture pieces

T.V Unit, 2-single bed, 1-double bed with storage , coffee table, study table, wardrobe.

1- bed with storage,1-charpai Plastic stackable chair, Coffee table, wall inbuilt wardrobe.

Sofa with storage, coffee table, folding dining table, 1double bed with storage, wardrobe

2-Single beds, wardrobe, study table.

Table, study table for kids, 1single bed,2charpai, coffeetable, wardrobe,TV unit

Eating preference

On floor

On floor

On floor

On floor

On floor

Preference to have dinning table

No

No

No

No

Yes

Preference for sleeping on bed /floor

Bed

Bed

Floor

Bed

Bed

Preference for storing things without a furniture piece

Loft storage, above floor, stacking on top of other

Loft storage, above floor, stacking on top of other

Loft storage, stacking on top of other

Loft storage, stacking above floor/wardrobe top

Stack above floor, stack on top of other.

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Dinning preferences dinning preferences on floor

dinning preferences on table

storage preferences in livingroom single bed with storage

single bed without storage

double bed with storage

double bed without storage

20%

25%

35%

75%

Ratio of people to space available in house Suffiecient

storage prefernces in bedroom

Less Sufficient

More than sufficient

15%

65%

80%

sleeping facility/area for guests on bed in living room

seating furniture used in case of more guest

on floor in living room

25%

15%

people using plastic stackable chair

20% 65%

75%

people using unstackable/other type of chair

85%

space used for maximum time living room

other rooms

sleeping preferences on floor

stacking preferences in house

on bed

13%

10%

25%

20%

top of cupboard under singlebed in built storage in wall

24%

loft stacks

90%

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80%

7%

31%

floor stack

User Study Insights User is in need of furniture which will provide storage

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Insights No provision of lofts, less carpet area , in flats compare to the no of people using the flat resulted using the space below beds, space above cupboards for storage.

Due unavailability of satisfactory furniture, people themselves trying to come up with there own solutions to the problem of Space constraint.

Analysis

(for custom made sofa cum bed`)

Accommodates five people Allows to use maximum floor space in living room Complex to access/operate Ergonomically poor Less comfortable

Analysis (for custom made beds) 1bhk Family members

3-4

2bhk 5-6

7-9

3-4

5-6

Weekly use of living room for sleeping and accessing storage Daily use of living room for sleeping and accessing storage

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7-9

Very less space for movement around.

Neat but Chaotic space.

Less floor space available after putting all furniture pieces.

Some times Less space + compromised design restricts the way it has to be used.

Satisfaction? does it give personal feel?

Relations? â&#x20AC;&#x201C; does it (product/environment)help to improve their interaction? Relaxation? Homeliness ?Ease?

Activity mapping of spaces in house In a middle class segment in India(focused on bedroom & living room)

Kitchen

Serving From kitchen to living room In case of guests

Living Room

sitting

Serving From kitchen to living room In case some family member is Not well

Overlapping activities

Having food Small talks over Siesta having food or tea/coffee Sleeping Entertainment Sleeping(in versatile space) Reading writing Gathering of guest Using laptop Writing Reading Storing

Bedroom

Sleeping (in private space) Dressing Storing Reading Writing Using laptop

Love Making Intimate activities

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Rate Of Recurrence Of Activity And There Interrelation

entertainment

Insights for living room

siesta

Eating food

sitting

Writing, reading, browsing mobiles

sleeping

Get-together, discussions, chatting

Serving from kitchen

Storing, Accessing storage

Social space in house User case Studies shows that â&#x20AC;&#x2DC;multifunctional special product - solutionâ&#x20AC;&#x2122; is needed.

There is an opportunity to merge regular daily activities associated with available space in an urban residence of lower and middle income group in India.

E.g. combining dining/having small meal and get-together/sitting Important to fill the gap between need of multifunctional special product-solution and its value in terms of aesthetics, comfort, flexibility, accessibility, usability etc.

Experience giving pleasure of Collective Relations Simultaneous Dealing with Interface Jointly Mind Relaxation Informal Homeliness Ease Comfort

living room as a shared space

Use of spaceThe living room is associated with regular activities like sitting, = group of 2-9 Having food = lunch/dinner on single bed or sofa some times on floor Small meal is preferred to have on sofa/single bed study = reading, writing, using laptop sleeping, = during night for guests who comes for weekly basis, Afternoon siesta Entertainment , = watching TV., listening to music, Get-together = discussions,chatting,interaction,entertaning guests,Serving from kitchen,

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Versatility of Bed room as a private space Insights for bed room dressing

siesta

Rate Of Recurrence Of Activity And There Interrelation

sitting storing

Intimate activities Writing, reading sleeping

Self study

Serving from kitchen

Personalized product- solutionâ&#x20AC;&#x2122; is needed.

There is an opportunity to merge regular daily activities associated with available space in an urban residence . E.g. Integration of resting space with study, reading, medicating Create the opening to fill the gap between need of multifunctional special product-solution and its value in terms of aesthetics, comfort, flexibility, accessibility, personalization etc.

Personal space Experience giving pleasure of Singular Relaxation Personal Homeliness One to one Ease Individual Emotion Sharing personal thoughts Personal space Pleasure Dealing with Interface

entertainment

Bed room as a private space Use of spaceThe Bedroom is associated with regular activities like sitting, = group of 2-3 study, = reading, writing, laptop using sleeping, = private space for couple, couple + kid Using accessories like alarm-clock,mobile,cup,plates,medicines near the bed Storing = storing clothes,bedding,blankets etc.

Medication = Serving from kitchen,Taking food/drink during medication period of family member.

Dressing = storing accessories related to dressing,changing clothes, hanging used clothes Lovemaking/ intimate activities

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Living room layout sdudy

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Zaltmans Metaphor Elicitation Technique

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Zaltman Metaphor elecitation technique The Zaltman metaphor elicitation technique (ZMET) is a patented market research tool. Patent was issued on July 25, 1995.

ZMET is a technique that elicits both conscious and especially unconscious thoughts by exploring people’s non-literal or metaphoric expressions. It was developed by Dr. Gerald Zaltman at the Harvard Business School in the early 1990s. As Zaltman described it, “A lot goes on in our minds that we’re not aware of. Most of what influences what we say and do occurs below the level of awareness. That’s why we need new techniques: to get at hidden knowledge-to get at what people don’t know they know.”

The technique has been used by academic researchers and for marketing purposes to study a variety of topics related to both marketing and the social sciences.

The ZMET research process Research study participants are usually asked to collect a set of pictures that represent their thoughts and feelings about the topic of interest.

Zaltman cites prominent researchers like Steven Pinker and Antonio Damasio to support his claim that humans think in images – often in the form of visual images – rather than in words. The pictures that participants collect are important non-literal devices for uncovering deeply held, often unconscious, thoughts and feelings.

The goal of the ZMET interviews and analysis is to uncover the relevant fundamental structures that guide people’s thinking about a topic. These deep structures are unconscious, basic orienting frames of human thought that affect how people process and react to information or a stimulus. They manifest themselves in surface metaphors used in everyday language and conversation; when grouped they point to the deeper frames or structures a person is using to understand a topic.

These frames can be used in a marketing context to help marketers communicate more effectively to consumers about a brand, product, or topic

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For diploma project this research methodology was conducted with the help of my guide Krishnes sir, to study the buying habits of user.

As per the research process I collected a set of pictures which represents “what the user think when they buy a piece of furniture for thier home.”

I could see a same pattern of thoughts in every individual , when pictures were grouped together.

In design process I tried to incorporate these framed unconscious thoughts.

FLUIDITY RHYTHMIC FLOW ORDER IN SPEED ARRIVING BALANCE WITH RICHNESS AND STILLNESS

PAMPERING SOLITARY CARE SELF INDULGENCE EASY,READY

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SOFT YET OVERPOWERING ACHIEVING BEING ARRIVED POWERFUL

PERFECTION PRECESSION DETAILING GRANDURE

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FESTIVE CELEBRATING

THROUIGH COMING TOGETHER TO CREATE AN

EXCLUSIVE WHOLE BONDING

ROYAL CENTRE GETTING NOTICHED

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Market Scenario

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The OEM - supplier relationship The business of the Furniture supplier functions as the process given belowIn one case, the OEMs share the designs with the suppliers. Then after product engineering, the production of the units is done, assembly, integration and dispatch follows.

In other case, the complete design and development is done by the supplier based on the OEMs requirements. The product is either built by using existing platforms or new product platform(s) may be introduced as per the market needs. When built on proven platform the design is taken forward to engineering and production stage which is followed by assembly integration and dispatch. For new product platform(s), the designs after product engineering are first tested and proven with the help of prototypes and after multiple reviews they are taken forward to production phase.

Sofas and beds in Indian market Visits to brand stores like Godrej Interio,Home Town, Housefull, Evoke, Happy Home Furniture in Ahmedabad opened the perspective in the Bussiness of sofa & Bed in Indian market.

The thought was to study capabilities of both the furnitures i.e. beds and sofas and apply ease,comfort of both furnitures to users experience possibly through single piece of design.

Market study helped to understand which type of furniture is most popular in customers so as to give direction for further ideation guideline.

This study helped me to understand which bed/ sofa sizes/types are mostly used in Indian middle class segment as per their need. What Material is preferred in bed designs mostly? Which material is preferred in sofa designs by this segment.

Insights

• In case of beds, Manully opereted storage beds and Hydraulic storage beds are available in maeket.Out of whitch Hydraulic storage beds are preferred by more users.

• Material and Hardware used in beds are Hydraulic lifts ,knock down fittings,metal frames,some times drawer channels.

Boards-Plywood,mdf,mmdf,particle boards • Queen Size bed(1800x1500) with storage is the most saleable one.

• Sofa cum double beds are available but segment considered for this project cant afford and the available designs are not able to fit into their houses.

• Sofa cum single beds are not available in market.

• Hardware used in sofas (details on page 70-71)

The potential of the any new product proposal needs to be in-sync with the market demands & possibility of it being a successful business decision.

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Market analysis of sofa cum beds Aspects considered: Ergonomics, Ease of operating mechanism, Size, possibility to fitting into room layout, Life of mechanism, Life of materials,target User’s lifestyle • Backrest is missing in the design • Mechanism is easy to operate but the guaranty life short.

• Material used for cushioning are not alike.

• Seat depth is more. Hence the purpose of having hand rest is inadequate.

• Placing against wall is thought of.

• Mechanism involves number of members.

1

• Backrest is converting into sleeping surface,while operating this backrest whole furniture has to shift in front against wall to make it as bed which will consume human efforts every moment.

• Mechanism is difficult to operate but the guaranty of life is more as very strong metal sections are used alike bed metal frame.

• Hand-rests are not provided in the design.

2

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• Sofa language is maintained in this option very well. Backrest and handrest is worked out well.

• Folding mechanism is not that convenient as compare to the language of sofa.

• Spread of the whole furniture is difficult to fit into the living rooms of target segment users.

• Market pricing for these designs are from 45000 rs-56000rs Per sofa.

3

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• Scandinavian company called innovation makes this model - Cubed 140 double sofa bed .

• Such products with great values are unaffordable for the target user.

• This particular furniture piece is space saving design so storage concern was not there as the context/target user is different.

4

• This sofa cum bed is designed by Happy Home furniture,S.G. Highway,Ahmedabad.

• It is serving storage,seating and bedding facility.

• Oversize for the target users average room size as well as expensive.

5

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Sofa and bed Market analysis India - Ahmedabad Type

size

price

Dedicated space for furniture in home

Most sellable in market

Type of sofa available in market Sofa 3+2 seater, Sofa with lounge 3+2 Sofa cum bed with storage Sofa cum bed without storage

1880 X 965 X 695mm 1800x1200 1800x1200

Types of material used for sofa

Wood/Plywood frame, PUfoam, fabric, leather, nails, metal plates

3000rs - 4500rs

Queen size bed without storage Queen size bed with storage King size bed without storage King size bed with storage

1800x1200 1950x1500 1950x1800 1950x1800

6,000rs - 20,000rs 16,000rs - 74,000rs 30,000rs - 75,000rs 20,000rs - 84,000rs

Types of material used for beds

Wood,Plywood, Particle board ,MDF board, MMDF boards ,Knock down fittings

15,000 rs - 80,000rs 45000rs - 1,00000rs 18,000rs - 36,000rs 20,000rs - 56,000rs

Living room Guestroom

Sofa with lounge 3+2 30,000 Rs -1,00,000 Rs/-

Types of beds available in market Single bed Bedroomh

Queen size with hydraulic storage22,000Rs/-

Queen size with manual storage of drawer 25,400Rs/-

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Traditional sofa making.

A visit to Mahavir Furniture Paldi, Ahmedabad.

Approximate cost per frame

3000-4500rs/piece

It is labour based industry where skilled/semi-skilled workshop setup runs the complete start to end production process.

Its a small space almost 2500sqft area which houses carpentry and lining work This workshop runs on contract basis with 6 workers and one contractor

Pu/ Rexene/ cotton 10-15m cost Varies from

100-500 rs /sqft

Lining work cost In case of special form

500rs to 1200rs 2500rs

First wooden frames are kept ready.On them metal strips/plate are fixed with nails.

Teak-wood frame 300x300 thk Mdf board 4mm thk Nails, nut & bolts 12mm thk plywood makes the Hole frame ready to cover up with foam.

Metal springs are stretched over frame.

• 25 sofas including frame work can be manufactured in a week time.

• 3-4 people work simultaneously for same work.

• Keeping stock for each design is not possible.

• Manufacturer try to achieve Maximum type of shape and form in sofa.

• Customization in size ,colour, texture is highly appreciated .

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Feather foam(local foam sheet brand) -1 inch,2 inch,4 inch,15mm are mainly used.

4 inch foam is mainly required for cushoining.1 inch foam is used for shaping the sharpness of 4 inch foam to achieve required curvature in sofa.

Armrest shapes options

Metal legs are fixed in the end with help of screw.

Staggered - interlinking of spring is done .

White coloured jute cloth is fixed on spring to hold foam so as springs will not tear the foam.

Upholstery is finally stitched with Staple- gun.

Pins are stapled in a way So that they are not seen.

Material

Size

Quantity

plywood

8x4

3 sheets

Teak wood sections

300mmx300mm thk

18 no

MDF sheet 4mm thk

450mmx600mm

2

Sewing machine is used to stitch upholstery partly before they are wrapped on foamed frame.

Plywood and Wooden frames of sofa creates empty spaces beneath.

Insights: • It is labour intensive work process.

• By this traditional method same frame cant be used for different customization option in overall look and form of the sofa.

• So to reduce production time ‘Standard frame’ making is not the solution.

• In this process final form is completely dependent on framework.

• Framework is made up of three different materials. Plywood,wood and mdf(me dium density fibre).

• Due to unavailability it difficult to maintain same carpenter to keep the quality same over the time.

• Space constraints to keep the stock for every design.

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Bed And Sofa Size Study

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Hypothesize

Material Process

Market survey

Rototmolding with LDPE-

In market there is wide range available for customer to see and buy any product/furniture.

Product is suppose to be mass manufactured.

Rotomolding is Cost effective over any other molding process like injection molding and blow molding.

Wide rang of design of a single product is possible because molds are relatively inexpensive.

Material wastage is less so comparatively economical.

Suitable for hollow and one piece structure.

Ready to use product is possible to manufacture Smooth working edges , Curvy forms are easily possible.

Provision of joinery, inserts are easy to mould in, so there is possibility of less labor cost and self assembly by customer.

Economical factor: Frame of product/furniture for 5 people should cost below or up to 3000 to 4500 Rs/-

Type of sofa most sell-able in Current Market: Sofa with lounge 3+2 Sofa 3+2 size – 1800x 600(72”x24”) Lounge-1800x760 (72”x30”) Cost (30,000Rs-1,00,000Rs) Type of sofa least sellable in Current Market: sofa cum bed with storage- size(1800x1200) cost- (20,000Rs-56,000Rs) Sofa with storage is not available.

Type of Bed most sell-able in Current Market: Queen size bed with manual storage size(1950x1500x450) cost-(25,400Rs)

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Storage is needed in living room .It should be given in the same product due to less of space available in a tenement compare to the members in family.

Formal Seating space for more than 7 people is needed.

Economical factor: User is willing to pay for this particular product 8000-15000 Rs/-

Need of economical solution

Scope to give economical solution

3 seater sofa min = 1800(72”) 2 seater sofa min =1320(52”)

For middle income group in India Residing in1BHK & 2BHK. Living room space needs a product allowing formal seating in day time & the same product allowing to sleep separately for two people in night time.

User in

process has

Comfortable seating=525(21”) Armrest height =180-225(7”-9”) Backrest =300-400(12”-16”)

User survey

Sleeping space for single person =1900x965(75”x38”) Sleeping space for two =1900x1370(75”x54”)

Considerations for Living Room size In 1HK & 2BHK Longer side = 19’ Shorter side = 8’ Geometry of room size is rectangular with ratio from 1:1.3 to 1:1.9

Redefined Design briefTo design single bed with storage for Indian middle class which will be used as sofa in living-room.(a sofa cum bed with storage having single person sleeping area.)

The user should be able to use the furniture in day time as a sofa for 3-4 person seating.

Detail features are discussed in next page.

With the guidelines of mass manufacturing process of Rotomolding -the fastest growing plastics processing methods.

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Comfortable Seat(3-4)

Provision for keeping Books

Extra Attached Writing pad

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Comfortable sleeping space(for one)

Main Attributes Enhanced Attributes Provision to keep things like spectacle ,wrist watch

Storage

Ideate

Light presence that can hold the small living room Modular sofa that will serve the multiple usage

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Initial concepts

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Insights After studying sofa types from market,there was need to rethink for thier sizes to fit into current living room size .

So thought was by fixing one persons required seat size,and multiplying that to no of required people may give modular design system solution..

So this table was prepared to have an fixed direction to follow.Which in the end couldn’t help directly but gave an idea to derive the perfect size for the proposed design.

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Sofa

Sofa with storage

sofa cum bed with storage

Sofa

Sofa with storage

Family of 2-3

Family of more than 4

Over all size for single person(seat pan)

21”x21”

21”x21”

Seat height

16”

18”

16”

18”

Arm rest size (If required as per design)

4” to 5” thk

4” to 5”thk

5” to 6” thk

5” to 6” thk

10” high from seat

10” high from seat

backrest

12” , 14”,18”

12” , 14”,18”

12” ,14”,18”

12” , 14”,18”

Length of sofa

21”x 1,2,3 + hand rest on both /one side/none

21”x 1,2,3 +hand rest on both /one side/none

24”x1,2,3 +hand rest on both /one side/none

24”x1,2,3 +hand rest on both /one side/none

Living Room size

Longer side = 19’ Shorter side = 8’ Geometry of room size is rectangular with ratio from 1:1.3 to 1:1.9

Bedroom size

Longer side = 12’ Shorter side = 8’ Geometry of room size rectangular with ratio from 1:1.3to1:1.5

6 ‘x 4 ‘ (for two people)

Family of 2-3

Family of more than 4

24”x24”

24”x24”

6’8”x4’8”

sofa cum bed with storage

6’6”x 5‘ (for two people) 7’6”x6’

Insights • This option might save the product cost and the effective usable space of room because storage box bellow seat is smaller by 100mm in depth.

• But the hassle of shifting/aligning the bed to wall is there.

Insights • In this option user is getting the more space to store things.

• Furniture is aligned in both the positions Sofa and Bed.

Option A

Rotating backrest along with cushion

Option B

Slide seat - rotating back push to open drawer storage

Option C

Only rotating backrest over complete single bed size seat with(no cushion)

Option D

Sliding(like train track)to access storage.

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Option A This option has Storage box, connectors from both the side, drawers to access storage,adjustable backrest working against wall without hitting

Rotating back rest to convert it into single bed with cushion attached.

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Option C This option has Storage box, connectors from both the side, drawers to access storage,adjustable backrest which cant work against wall.

sliding drawer for storage

rotating backrest with adjusting flap

These basic three guidelines were finalised to explore some more mechanisms and reach up-to a final outcome

Seating Position

Sleeping Position

Accessing Storage Position

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Option A

Exploring mechanism alternatives to those available in market for the sofa cum bed is very important because that is the core of the Furniture as its working Efficiency was dependant of it.3-4 concepts for this purpose was explored.

Junction

link

track

1

4

2

5

Insights Junction of seat and backrest still have little problem.

Mechanism consists of one link ,one track.

Sliding mechanism is happening very abruptly it has to work gradually to avoid collision and injury to user.

Mechanism has to be concealed.

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3

Option B Insights

In this concept seat and back rest are attached to one monolithic metal joinery in which mechanism has been worked in a way to facilitate backrest rotation only.

Seat remains at its position but to convert sofa in to bed one has to pull the backrest with hands..

To access the storage one has to lift the seat.

1

4

2

3

5

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Option D

• In this concept, seat along with its backrest is imagined to be moving on tracks like train.

• There are two tracks. One is along the seat and one is along the hand-rest structure.

• Metal Track is fitted at the ends of seat to hand rest section through which plastic sections are sliding with Pu foam attached to it.

• The movement will happen by pushing the seat while sitting on sofa.

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1

2

3

Bed position

Lock needed to stop the sliding in sitting posture

Insights

• Good aspects of this option is playfulness of the mechanism.

One can access the storage below the seat by sliding the track while seating on sofa.

• Locking of the track is tough job to work out in terms of engineering and making it cost effective in terms of mass manufacturing.

• Regular use of track is mandatory so its joinery has to be wear & tear free.

Track changer to convert it into bed

4

5

sofa position

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Finalised concept Insights Ease of folding/unfolding the cushion in gradual manner is possible with hydraulic lifts.

So for both the purpose i.e. to access storage and to convert into bed different capacity hydraulic lifts are used. metal links are used to stop the motion at required angle.

1

2

3

Hardware used for folding purpose 4

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5

Finalised concept refinement.

Plan (box structure)

Section at b

Section at a

Elevation

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Detailing explorations for Hand-rest box Attached Pad to write

Space to keep books Size 150mmx225mm

Lamp provision for reading in night time while going to sleep space to keep alarmclock, wristwatch,stionary like pens,pencils

Space to keep books Size 150mmx225mm

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Detailing explorations for Storage Box

Storage Box detail Hand-rest to box connection detail explorations

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Form Exploration for Armrest and backrest integrated

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Form Refinement for Armrest and backrest integrated

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Form Refinement for Armrest and backrest integrated

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Form Refinement for Armrest and backrest integrated

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Product Renderings

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Product Renderings

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Product Renderings

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Rotomolding Furniture for living room

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Rotomolding Furniture for living room

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Rotomolding Furniture for living room

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design

Rotomolding Furniture for living room

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Bibliography http://cncrouting.co.uk/ http://caravansplus.com.au/catalog/index.php http://www.lusch.de/index.php?id=160&L=1 http://www.iqsdirectory.com/blow-molded-plastics/ http://www.oldtowncanoe.com/craftsmanship/ http://www.woodmagazine.com/community/ http://www.poynters.co.nz/ http://www.amsautomotive.com/AMS/index.asp?DBID=1&LNGID=1 http://www.dbresearch.de/PROD/DBR_INTERNET_DE-PROD/PROD0000000000253735.pdf http://en.wikipedia.org/wiki/Zaltman_metaphor_elicitation_technique http://www.olsonzaltman.com/process.htm

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Neelam Khetmar// Diploma Document // 2011 Batch // National Institute of Design