2024
Reclaimed Plywood
Design for Manufacture Research
03. ReFrame
Amidst a growing global wood shortage driven by escalating demand and finite natural resources, the exploration of utilizing wood waste is an increasingly prominent topic in the fields of architecture and design.
In response, a modular furniture collection has been developed to investigate the research question: To what extent can tailoring products utilize variable wood waste with the consideration of resource efficiency?
In response, a modular furniture collection has been developed to investigate the research question: To what extent can tailoring products utilize variable wood waste with the consideration of resource efficiency?
The design began with evenly spaced joints on all components for maximum flexibility. However, this demanded high precision and caused material waste. To improve efficiency, components were split into structural and connecting types. Each connecting component incorporates five joints: four enable secure connections with structural components, while the fifth links two connecting components together.
To further optimize material use, only essential joints are CNC-milled, while straight cuts are made with a bandsaw. With only one joining point for all components to minimize the use of materials and parts, stabilizing the structure is essential for functionality. To achieve this, a series of tension structures with varying string connection techniques were simulated in Karamba.
After real-life testing, the best solution was selected due to its effectiveness in maintaining structural integrity. The final unit is highly adaptable—capable of stacking vertically, extending horizontally, or standing alone—making it suitable for diverse, space-efficient design applications.
The design uses a step-by-step process to turn irregular wood offcuts into usable components with as little waste as possible.
It begins with digitally arranging the components on each wood piece to find the most efficient layout. This is done using software tools like OpenNest and Galapagos, which test many layout combinations to find the one that uses the most material and leaves the least scrap.
To further reduce waste during the making process, only the most precise part are cut using a CNC router, which is a highly accurate digital cutting machine. Simpler cuts, like straight lines, are done with bandsaw to save time and material.