BASAL
SUNLOUNGER
PROJECT DOCUMENTATION
SARC 312 A progression of work from SARC 212
THE BASAL SUNLOUNGER YASMIN STEWART
INTRODUCTION + DESIGN CHALLENGE
The design must now be refined and revolved to pre-production specification.The challenge for this project is to define a thoughtful innovative item of furniture from previous concept research and investigation. It should be resolved to a high level of visual sophistication. The aim is to communicate design intent of the final artefact (product) to the client and advance personal knowledge and skill set available to professional designers in the development of furni-ture. Topics covered will include; specification and documention methods, product and produc-tion costing.
DESIGN AN OUTDOOR FURNITURE PIECE
The client for this project is Accoya Timber (supplied in NZ by Timspec) and therefore the the end design will be constructed largely from this material and will strive to highlight its strengths as a material. ‘Accoya® is the world’s leading high technology long life wood. Created via acetylated wood modification, using sustainably grown timber, the Accoya® process is non-toxic. It enables nature and creates a modified wood that matches or exceeds the durability, stability and beauty of the very best tropical hardwoods.The Accoya® wood production process takes sustainably-sourced, fast growing softwood and, in a non toxic process that ‘enables nature’, creates a new durable, stable and beautiful product, a ‘treated timber’ that has the very best environmental credentials.’Benefits of AccoyaClean burning, is affected very little by UV, less prone to rot, 50years above ground 25years below, dimensial stability, coatings perform better (than standard timbers)
CLIENT; ACCOYA
TRIIGERS + PRECEDENTS
“DONT UNDERESTIMATE THE VALUE OF DOING NOTHING, OF JUST GOING ALONG, LISTENING TO ALL THE THINGS YOU CAN’T HEAR AND NOT BOTHERING”A.A. Milne
TRIGGERS
To use the medium of outdoor furniture to create a sheltered space in which one can feel both physically and mentally removed from their surrounding environment.To promote physical and mental relaxation through decreasing of sensory factors(sights and sounds) and provide a mental shelter from the chaos of urban density.
To be situated along the wellington waterfront in the heart of the cbd. Target demographic is week day buissness peoples whom often hurry around the waterfront running errands during middainstallation will provide a resting place for these people to collect their thoughts and take a break from the hustle and bustle of everyday life.
DESIGN OBJECTIVE
CONTEXT / SITE / END USERS
ORGINAL CONCEPT DEVELOPMENT
This design promotes the idea of being able to seclude oneself from the hustle&bustle of a busy public area. The laid back form of the lounger relaxes the posture of the user while the head box visually removes the sights of the public instantly easing the stress that can occur from too much human interaction. The box is designed to let users take a breather in their own private, enclosed space. The window gives a clear, simple focus point(the sky) on which to conentration and calm the mind and body. The hood is designed to be pulled and out, to allow easier access up and down from the lounger and also as a less secluded seating space. This design aims to provide stressed out passers by with a small area of sheltered privacy in which to reagin their thoughts and posture.
HEAD IN A BOX
INITIAL CONCEPT
MATERIAL RESEARCH
‘The physical properties of any material are determined by its chemical structure. Wood con-tains an abundance of chemical groups called “free hydroxyls” (represented as OH in the picture). Free hydroxyl groups adsorb and release water according to changes in the climatic conditions to which the wood is exposed. This is the main reason why wood swells and shrinks. It is also believed that the digestion of wood by enzymes initiates at the free hydroxyl sites – which is one of the principal reasons why wood is prone to decay.Acetylation effectively changes the free hydroxyls within the wood into acetyl groups. This is done by reacting the wood with acetic anhydride, which comes from acetic acid (known as vinegar when in its dilute form). When the free hydroxyl group is transformed to an acetyl group, the ability of the wood to absorb water is greatly reduced, rendering the wood more dimensionally stable and, because it is no longer digestible, extremely durable’ -’Creating the Worlds’ Leading Acetylated Wood’ http://www.accoya.com/acetylated-wood/The client for this projecct is Accoya Timbers of Timspec NZ, therefore the primary construction meterial shall be Accoya timber. Accoya is a treated wood and there-fore has a unique set of qualities.
DEVELOPMENT SKETCHES
40’
CONCEPT DEVELOPMENT
From Project One I have decided to develop my initial design further by taking more into consideration the ergonomics and functionality of the design. Issues that need to be addressed are; the ease of use, getting in and out, the possible feeling of claustrophobia one might have; ergonomics of the reclined position, material processes used.The focus charachteristics of the design will be; ergonomics, comfort, relaxation and environ-mental justification.
Form + Struction + Aesthetic
SKETCH MODELS
1:1 SCALE CARDBOARD MODEL Testing the scale of the model and design of the form
DEVELOPMENT DRAWINGS
RETHOUGHT-DESIGN OBJECTIVE
To use the medium of outdoor furniture to create a form that is both aesthetically and physically relaxing. To allow the user maximum body relaxtation through the use of ergonomic and elongated, soft forms.To intergrate the this piece of furniture into its intended environment in a subtle, respectful manner. To produce a design that is economical to manufacture and can be utilised by the every-day man
Technical drawings of the design to communicate dimmension and form
PRODUCTION METHODS SEAT
BACK-REST Accoya Timber 200 x 50 @ 4400
SLATS
JIG
Cut to 1100mm lengths -Drop Saw-
Accoya Timber 100x50@1400
MDF 2400x1200x18
Machine flat surfaces -Planer + Thicknesser-
Cut to 2000mm lengths -Drop Saw-
Cut to 25mm width -Table SawProfile cut slat shape -CNC Mill MachineMachine slats to exact same shape -Belt Sander-
Profile cut jig shape -CNC Mill Machine-
Machine Flat surfaces -Planer + ThicknesserCut into 5x45 laminates -Table saw + Planer +Thicknesser-
Drill holes for rod inserts -Drill Press + Jig-
Assemble jig Laminate 3xjig profiles Secure to work bench
Cold Form Slats Clamp 7x(5x45)laminates into jig Glue for 6-10hours -West Systems AdhesivePlane flat, even surfaces -Hand grinder + Belt SanderDrill holes for rod inserts -Drill Press + Jig-
Cut threaded rod and aluminum tube -Steel Cutter + Hack Saw + FileAssemble
BACKREST CONSTRUCTION Units in mm
STEP ONE
30
CNC cut profile shape out of one solid piece of 200 x 25 @ 1m *Order timber at lenths of 1.1m to allow room for construction error *Design requires 7pieces of aforementioned timber, order one extra for possible construction errors
1000.00
200
0.00
110
Accoya timber order: 200 x 50 @ 4400 or 4pieces of 200x50 @ 1100
50
25
200
SEAT CONSTRUCTION
45
45
Units in mm
x7
=
5 35
STEP ONE
STEP TWO
Cut timber into 45x5@2000.00 7pieces of 45x5@2000.00 makes one 35x45@2000.00 slat Design uses 8slats, hence 56pieces of 45x5@2000.00 are required
Laminate 7pieces of 45x5@2000.00 in cold formers Set using West Systems Epoxy Glue
0.00
200
*Length has been rounded up to 2m to allow for overhang Accoya timber order:
50
100 x 50 @ 14000 or 7pieces of 100x50 @ 2000 *estimate allows for 5mm wastage material per cut from saw blade+ extra lengths for spare material
100
45
09
107. Ø 35
10 45
1753.37
27
992.26
440
530
BASAL LOUNGER units in mm
407.53
45
1713.47
530
45
1753.37
SEAT
units in mm
45
80
445
751.27
.53
944
79
. 161 25
45
25
10
BACKREST units in mm
Aluminum tube Threaded rod
A
DETAIL A SCALE 1 : 10
2mm Washers Threaded rod
B
DETAIL B SCALE 1 : 10
END OF SLAT CONNECTION
ROTATIONAL JOINT DETAIL
DIMENSION DRAWINGS 1. Headrest
2. Under seat shelf
3. Seat
All Material : ACCOYA TIMBER
4. Lumbar support
units : mm
5x
57.00
25.00 x 70.00 x 941.00
941.00
25.00
0
25.00
.0 941
610.00
70.00
25.00
TOP
0
70.0
FRONT
LEFT
1.
ISOMETRIC
4x
25.00 115.00
33.00
25.00 x 33.00 x 488.00
0
25.00
8.0
48 33.00
488.00
2. FRONT
TOP
4. Lumbar Support
RIGHT
5x
0
1872.00
70.0
.00
25.0 0
390.00
70.00
25.00 x 70.00 x 1872.00
72
18
70.00
RIGHT
TOP
FRONT
3.
ISOMETRIC
4x
342
33..00
25.00 x 33.00 x 952.00
.00
0
952
25.0
373.79
3. Seat
25.00
2. Under seat shelf
25.00
1. Head rest
ISOMETRIC
33.00
952.00 0
33.0
4. TOP
FRONT
ISOMETRIC
RIGHT
DRAWINGS; as sent to Woodform Design Ltd
OUT-SOURCING MANUFACTURE
During the first stages of manufacture planning I looked into outsourcing for my woodbending. Dave Pratt of Woodform Design Ltd was one of the people I spoke to about how I could get components of my design constructed. Woodform Design Ltd is an Auckland based company who, for the past twenty-five years, have been manfacturing bent wood components. ‘Woodform Design has pioneered research into technology to develop systems for the bending and shaping of solid timber’. I sent Pratt drawings of my intial designs(see next page) including measurements and requested a quote for the production+freight costs for the pieces I wanted; ‘ Each of these components is bent to a different shape and repeated five times eg. five pices of 70mm(width) x25mm(depth) x730mm(height) bent to the mould of Component One. Initially I had planned to steam bend and laminate these pieces however after looking through your website I see you have a wider range of techniques available therefore if you think another technique would be better applied I would be greatful for your reccomendations. (Yasmin Stewart)’. Pratt gave me a quote for the work (see below) and noted that they required two protypes to be made in order for the job to fit their business model criteria. Later changes in the redesign of my model meant that ultimately outsourcing to Woodform Design Ltd was not the most finacially beneficial path for me to go down, however Pratts quotes largely helped in forming a general idea of manufacture costs in the industry.
Dave Pratt Joint Managing Director Woodform Design Ltd 58-60 The Concourse, Henderson, Auckland P.O.Box 44-054, Pt Chevalier, Auckland New Zealand
SPECIFICATION:* Net ex factory exclusive of G.S.T. * Accoya / Pine in machine finish to size details supplied * Not cut shaped drilled or finished in any way * Laminated using 8.3mm laminates to give consistant shape * Includes simple jigs for processing, however should any more be required more substantial jigs will be required *Payment terms to be discussed * 70x25 x 941mm long 5 pcs. $435.00 * 33x25x488 long 4 pcs. $174.00 * 33x25x952 long 4 pcs, $174.00 * 70x25x1872 long 5 pcs. $591.00
RESPONSE/QUOTE
MANUFACTURE TASK ALLOCATION SHEET
PROJECT: The Basal Sunlounger Prototype by Yasmin Stewart
SEAT CONNECTION + ROTATION
-Placed behind the rotaional joint between the backrest and seat, blocks between the seat slats would prevent the backrest from rotating past that point. The benfit of this would be that the blocks would be hidden within the slats, visible from above but not breaking the curve of the design. This method however, would put a lot of strain on the WOODEN BLOCKING blocks and as a friction joint this could be too much stress on the joint causing it to fail. -Another technique that could be used would be to put another steel rod/tube behind the rotational joint, much like wooden blocking but aesthetically nicer, visualing linking to the tubing at the slat ends. Having a stopper STEEL STOPPER behind the joint may mean that when the backrest is rotated forward, the bottom end of it hits the stopper, thus preventing the from fully folding.
-A simple but effective way to solve the issue of keeping the backrest in the desired reclining position while still allowing for it to be rotated forward is to use a tension cable between the bottom of the beackrest and the back end of the seat. One long piece of cable is tied at one end the wound around the aluminum tubes between slats, zigzagging from the seat to the backrest. While the backrest is in an unpright, reclined postion the cable will be taught, providing tension to stop it moving whilst also distrubutuing the weight pressure amoun more slats. When the backrest is rotated forward the cable will simply be slack as it is not in use. Visually the ziggzagging pattern of the cable provides a nice balance to the simple wooden curves that are the majority of the design, this prevents the design from looking too visually heavy. The tension cable used is nylon rope, this material is cheap and easy to knot. It also has a slight stretch to accomodate for movement when weight is put upon it. An added feature of the design is that the rope can be tied to suit the induvidual users ideal relcine position. This is simply done by untying the knot and readjusting the chair.
TENSION CABLE
COSTING
Bill of materials for the Basal Sunlounger prototype. All prices have been done as accurately as possible.
PRODUCTION PROCESS IMAGES
OPEN SOURCE
The Basal Sunlounger is an open source design, designed so that anyone with access to a CNC machine can build their own and customize it to their induvidual taste. Files for the CNC-machined jig and profiles for the backrest slats will be available to download off the internet for a small fee with all profits going toward a selcted charity and planting new radiata pine trees to supplement the supply and demand. Accoya is the only material that must be specific in the design, it can be purchased via suppliers found at www.accoya.com. All other material; rope, fixings, adhesives and jigs, can be sourced locally buy the maker increasing economical growth within their community. Once the files are download and pieces fabricated, the maker assemble the lounger in a few short, simple steps. Assembly instructions will also be available for download. The lounger can be further sylized with different finishing methods applied to achieved the makers desired aesthetic.
STRENGTH The strength of the construction comes from the steel rod locking the slats together at each end and both components together. Seven 5mm laminates make up each slat, provided extra strength in core stress areas.
STORAGE + PROTECTION The ability to fold the back piece into the seat offers extra protection against the elements when left out side and also makes it easier to
KIT-SET
CUSTOMIZING COMFORT
Being kit-set the lounger can be flat-packed and economically shipped intenationally. It uses minimal materials making it easy to assemble and requiring only a 22mm socket for tightening fastners.
Using rope as a suspension cable to hold the backrest in a reclined position means that the user can adjest the length and in turn adjust the recline of the lounger so it can be suited to meet all comfort needs.
NATURAL BEAUTY ERGONOMICS
Accoya itself is a very eco-friendly proccessed timber as it is treated on a molecular level as opposed to chemicaly. It naturally has a 20+year outdoor life so no finishing treatments have been added to the Basal Sunlounger post-production. It has been hand-sanded to bring up the natural beautiful sheen
The Basal Sunlounger has been designed to fit the body ergonmically. The reclined position of the backrest provides support to the back, lumbar and neck while the seat is curved to elevate and support the knees.
OPEN SOURCE
VERSATILITY
The CNC files for the jigs and backrest profiles will be open source, allowing any one with access to a CNC machine to be able to make their own.
The Basal Sunlounger can be used in the home as a backyard sunbathing chair or commercially on a public waterfront. It is designed for relaxation, wherever that may take place
CRITIQUE
THE BASAL SUNLOUNGER
Relaxation through
Flow + Simplicity + Versatility
The Basal Sunlounger has an elegant aesthetic, inspired by the rolling waves of the ocean, crafted to the human body. The ergonomically considerate curves of the lounger are designed to fit the contours of the body in the most comfortable manner, with the tension rope adjusting to suit each user individually. Providing support for the legs, lumbar, back and neck allows weight to be distributed evenly throughout the body meaning all the users muscles get maximum relaxation. The Basal Sunlounger encourages users to recline, relax and rest. The flowing form of the wooden slats complemented by the zigzagged rope is visually harmonious, reminiscent of summer days spent beside the sea. Using minimal materials to maximum effect and exploiting the many benefits of Accoya-Acetylated Wood such as strength, durability, sustainability and natural beauty, the Basal Sunlounger is built to last. That slat construction of the lounger makes it lighter and more portable, with a fold-able backrest to make shipping and storage that much easier. Produced from laminates cold-formed in specially made jigs and CNC machined pieces, this design takes advantage of the flexibility and strength of Accoya, resulting in strong, tight curved slats. The backrest is held in place using rope as tension cable between the ends of the backrest and seat, this rope is flexible and allows for the reclining position to adjust according to the users weight. Constructed using minimal materials; Accoya, rope, threaded rod, aluminum tube and fixings that are familiar to the every-day man, the lounger is quick and easy to assemble. Held together by threaded rod and friction joints covered by aluminum tubing, the ‘mechanics’ of the chair are carefully hidden from direct view to make for a smoother aesthetic. The wooden slats have been hand-sanded to give a smooth soft finish while no chemical finishing treatments have been added post-production as Accoya has an in-ground life of 20+ years meaning it can weather any storm. Ideal for use both commercially and domestically, on a public waterfront, beside the pool or on the deck at home. The Basal Sunlounger is intended for just that, lounging in the sun may it be in the comfort of a your private backyard, beside the hotel pool or on the public waterfront during lunch break. Utilizing cost-effective production methods such as jigs and CNC machining allows for rapid production to meet market demands. Simple materials also mean that the lounger can be efficiently produced, internationally. The wooden slats can be made in any workshop that has access to a CNC router, original CAD files for the seat jig and backrest profile are simply downloaded and machined in Accoya. All other materials (rope, rod, aluminum and fixings) can then be sourced locally providing economical growth for the community. The Basal Sunlounger is about rest and relaxation, physically and mentally. Let its rolling curves support your body while you look skyward and relax.
FLOW+FORM
SIMPLICITY+CONSTRUCTION
VERSATILITY+MANUFACTURE
MARKETING EXPOSITION
Using minimal materials to maximum effect and exploiting the many benefits of Accoya-Acetylated Wood such as strength, durability, sustainability and natural beauty, the Basal Sunlounger is built to last. That slat construction of the lounger makes it lighter and more portable, with a fold-able backrest to make shipping and storage that much easier. The wooden slats have been hand-sanded to give a smooth soft finish while no chemical finishing treatments have been added post-production as Accoya has an in-ground life of 20+ years meaning it can weather any storm.
THE BASAL SUNLOUNGER
The ergonomically considerate curves of the lounger are designed to fit the contours of the body in the most comfortable manner, with the tension rope adjusting to suit each user individually. Providing support for the legs, lumbar, back and neck allows weight to be distributed evenly throughout the body meaning all your muscles get maximum relaxation. The Basal Sunlounger encourages users to recline, relax and rest. The flowing form of the wooden slats complemented by the zigzagged rope is visually harmonious, reminiscent of summer days spent beside the sea. Ideal for use both commercially and domestically, on a public waterfront, beside the pool or on the deck at home. The Basal Sunlounger is about rest and relaxation, physically and mentally. Let its rolling curves support your body while you look skyward and relax.
FLOW. SIMPLICITY. RELAXATION.
COMMERCIAL
The Basal Sunlounger is designed to be used both domestically and commercially. The Basal was designed to be in a social, waterfront context with the intention that passersby would be drawn to relax upon it while taking in the ocean scenery. The Wellington City Waterfront is a prime example of an ideal public location for the Basal Sunlounger as many buisness people use this acessway during the day whom would find the use of a space to sit and relax most fufilling. Another situation in which the Basal would be ideal is poolside at a resort/hotel, providing a seat in which to sunbathe by the pool. Designed to showcase the qualities of the Accoya timber the Basal is manufactured using a variety of production techniques, emphasizing the many ways in which Accoya can be manipulated. The way in which it enhances all of Accoya’s best qualities such as strength, flexibility, durability and natural beauty make it a perfect showcase design for the material.
DOMESTIC
The Basal Sunlounger is a piece of outdoor furniture that can be used both commercially and domestically. The Basal Sunlounger is designed to be easily assembled, trasnported and stored. With minimal construction components the lounger is made as a ‘kit-set’ with simple steps to put it together, esentially all that needs to be done to is to place the steel rod through the hole in the slats and secure each end with a srew. It’s unique folding ability allows the user to swing the back-rest forward til it locks into the seat of the chair, this makes transportation and storage much simpler. It can also be done to protect the surface of the seat from damage from the elements as it fold over the main areas, shielding itself. The soft curves of the design and the slated asethetic means that the Basal Sunlounger looks at home, at your home. Whether it be beside the pool, on the deck or in the garden the Basal Sunlounger exudes rest and relaxation with it’s elongated seat and reclined ergonomic curves.
PROJECT OVERVIEW
This design process has taught me much about various production methods, the properties of Accoya, time management, prototype costing, marketing methods and general industry practices. I believe that making a personal design, personally is vital for the the prototype, there are so many things I did not realise were not quite right until I started physically making the prototype, this included my original idea to have wooden blocks instead of threaded rod which I discovered were not strong enough and also not visually appealing. Working hand-on with Accoya made me realise it’s full potential as a material, I had initially thought I would have to steam bend my curved slats but found that the strength and flexibility of Accoya meant I could simply laminate 5mm pieces in a cold formed jig. This made the process much quicker and in terms of future production, much more economical. I have also learnt to utilise basic, low-cost materials to make a design that can be better marketed. A good design does not need to use expensive materials, but the materials it does use must be used with integrity and innovatively. I think that out-sourcing production is very useful for some aspects, after first considering every aspect of the outcome and triple-checking it will work. One thing I found that failed with my design was slight bowing in the slats as they did not all sit in the jig the same way and thus were ever so slightly different. To prevent this from happening again I would make small adjustment to the jig so that the two halves fitted into each other in one way making all pieces exactly identical. Another thing I would change would be to add metal caps over the fixings on the edges of the slats to make it flush, time did not allow for this to happen in the prototype but 3-d printed metal caps in a number of designs could be a step forward for the design. The project structure itself I have found reasonable, more prodction/workshop time during the beginning would have been preferred but unseen circumstances did not allow for this. Constantly reworking the design I think is great, but should be done both on paper and physically in equal ammounts. Every design can better itself, and this project has taught me how to explore and examine every aspect of a design to achieve full potential.
THANKS TO; -Nat Perkins -Dave -Nan -Victoria University Workshop Technicians -Timspec -Ryan Geels -Victoria University of Wellington School of Architecture and Design