Cache
Flat-pack stool and storage.
Project Brief
The intent of this project is to design and create a flat-pack/ knock-down stool out of a corrugated plastic sheet. By doing so, a number of structural principles and constructions for use in furniture will be explored. Conservation of material, material limitations, and design within manufacturing constraints are also to be explored in this project.
Limitations
The stool must be constructed primarily out of a 4′ x 4′ x 4mm sheet of coroplast (corrugated polypropylene plastic) that supports human weight. This seat must be a minimum of 16″ tall. The design and construction will also be constrained by a $4 budget.
Design Inspiration
Efficient flat-packing
Stable triangular construction
Comfortable seat
User-friendly assembly
Visually interesting geometry
Sketching and Modeling
Many of these experimental paper models were created by cutting slits into two or three surfaces and then joining them together so they intersect to create a center structure. As the concept progressed, inwardly folded triangles added extra stability. Triangles are used because they allow a plane to be secured using only three anchor points. This is essential in order to meet material and budget constraints.
Corrugated fiberboard models were used to fine-tune the final design, including its dimensions, types of fasteners, and the orientation of corrugations.
Cost Analysis
Cache
The stool contains four caches—discreet storage spaces for personal belongings. Cache is storable because of its simple disassembly and flat-pack design, and storage-able because of its unique stuff-holding ability. Its robust geometric design supports full body weight.
Assembly
The stool is made of only two pieces, which slide together to form the center structure. Then the six triangular segments fold inward, enveloping the center structure and becoming the seat. Each flap is pressed down, secured firmly by its hook and loop fasteners.
