The purpose of this project was to develop an innovative home furniture product that could be assembled without the need of glues or screws. I decided to develop a mix of a bench and a gazebo - a structure for private garden use that would allow you to sit or recline as well as shade you from the sun or rain. Core aims of the project were real life practicality, strong stability, simple self-assembly, and an outlook to profitable, cost-efficient mass production and series assembly.
I thought of how to tackle the challenge of designing a construction without needing any screws or any glue. I came upon the concept of sliding two modular frames into each other - as sketched above. Forming a cross from top-down perspective, this would serve as the "spine" or foundation of the entire structure. Next, I formulated four squares to slot into the cross at seating height for the foundation of the bench. Of course, sitting on these simply slotted in would be incredibly unstable and simply collapse. After brainstorming solutions, I thought of sliding in multiple "rib"-like frames that would would each slide into the bench square, reaching up to form a backrest, as well as reaching down into the ground and out - distributing and transferring the weight across the ground instead of down onto a singular, unsupported point. The ribs acted both as the "meat" of the structure, as well as the structural support.
I modelled the idea in AutoCAD, developing both 2D cross-sections which would be important later, and the 3D model.
Next, I ported my 3D model into Sketchup and Enscape, allowing me to render the entire model into a real life setting along with other objects, people, and with different sun positions and light settings to test the real life shading capabilities of my design.
With my concept modelled and proven in 3D, it was time to implement the idea into reality. I took the 2D schematics of each of the modular components, and laser cut them out of MDF wood sheets. Then, I simply slotted and assembled everything together. The result was a functional miniature prototype of the final model.
Summary, Evaluation, Learnings
After being presented with the design challenge, I researched and brainstormed multiple solution approaches.
Applying concepts like frame technology and kinetic weight distribution, I developed a design structure that was both stable and aesthetic, as well as practically useful and innovative by allowing for both cost efficient mass production and simple assembly due it being composed of just a few different variants of modular, repeating frames with no small parts, accessories or screws needed. This was it's main unique selling point.
I modelled the design in 3D as well as actualised it into real life materials and ensured it's a realistic, tangible, and scalable product idea.
The design proved suitable for series production with the modular components being manufacturable in bulk consistently and cost-efficiently. And with growing interest in sustainable and easy-to-assemble outdoor structures, the gazebo has good market potential, appealing to consumers looking for practical and stylish garden features.
This project gave me valuable experience in design solution thinking, product conceptualisation, structural engineering, and real world implementation.
Main softwares used were AutoCAD, Sketchup, and Enscape.