While pursuing my degree in industrial design at SFSU, I was challenged by my professor to create a chair using a single sheet of plywood and incorporating the CNC, laser cutter and 3D printer. Despite having limited woodworking skills, I embraced this hands-on project as an opportunity to learn and grow.
With only one chance to use the CNC machine, I had to methodically plan out each step of the process and anticipate any potential obstacles. Throughout the project, I consulted with lab technicians for technical feedback and my professor for insight on engineering principles.
My vision was to create a modern, functional, and aesthetically pleasing lounge chair with adjustable arms using T-nuts and 3D printed knobs. The final touch was to hand-sew the upholstery to provide greater user comfort.
Overall, this project was a valuable learning experience that allowed me to explore new techniques and materials. It reinforced my passion for industrial design and solidified my commitment to creating functional and visually appealing products.
2022
Fusion 360
CNC Machining
3D Printing
Laser cutting
Ideation | 3D Modeling | Prototyping | Visual Design
I started by interviewing 5 participants. I asked them questions regarding their sitting preferences and had them sit on a standard chair to understand ergonomic preferences .
Key findings
Design solution: Develop a chair that seamlessly combines comfort, modular functionality, and has an appealing aesthetic.
The visual research started by created a moodboard. I gathered various images of chairs, subcomponents, organic lifeforms and mixed media artwork that I found interesting and innovative.
Synthesizing the research lead me to identify various areas of interest.
To begin the ideation, I started with a healthy amount of sketching. I explored various concept and studied existing chairs to benchmark functionality.
To consolidate my ideas, I used a tablet to synthesize my major visual findings onto a single page. As I worked through my sketches, my vision for the chair started to develop. The most promising concepts are on the bottom right of the page.
After receiving feedback from potential users and my instructor, I drew a final orthographic views of the chair.
Once I had finalized my sketch, I used orthographic views to create a detailed CAD model in Autodesk Fusion 360. I wanted to ensure that the model was as accurate as possible, so I paid close attention to each detail during the modeling process.
To aid in the manufacturing process, I created a flat projection of the chair that showed all the subassemblies on a single plane. This allowed the CNC machine to read the file and cut the parts according to the necessary degrees.
The 3D model and flat projection provided a clear understanding of how the chair would come together, and allowed me to identify any potential issues or challenges early on in the process.
I reduced the scale of my model by 13% to facilitate laser cutting of the chair in a smaller size. This approach enabled me to evaluate proportions and scale before proceeding with the CNC cutting process, ensuring precision and accuracy in the final product.
With the CAD model and flat projection complete, I began the manufacturing process by setting up and running the CNC machine to cut all of the subassemblies. I carefully monitored the process to ensure that each piece was cut to the correct dimensions and angles.
Once the subassemblies were cut, I used a router to clean up any rough or raw edges. This step helped ensure that the pieces fit together smoothly and accurately during the assembly process.
One of the challenges I faced during the manufacturing process was learning a woodworking technique called kerf bending. This process involves cutting a series of slots on a strip of wood to allow it to bend into a specific shape.
To determine the proper spacing and depth of the cuts, I experimented on scraps of wood until I achieved the desired results. I assembled the chair and sanded the body for a smooth finish.
Special thanks to Robb Godshaw, Ida Lajevardi & Eduardo Flores!