Samantha Kong|




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MAGNOLIA

project type: Manufacturing
date: November 2024
duration: 2 months
skills: Woodworking, Adobe Illustrator, Adobe Photoshop




project description

The stool presents a bold interplay of geometry and structure, where stacked, hollowed cedar forms meet sleek steel supports. Its sculptural profile emphasizes the contrast between organic curves and industrial lines, while the exposed metal frame lends a sense of tension and stability. The design balances visual weight and functionality, creating a piece that is both practical and visually striking. 
brief
The objective of this project is to explore manufacturing processes and materials through designing and manufacturing a patio stool. Some requirements and contraints for the project were: to hold a weight capacity of 250lbs, select material and finish to reflect outdoor environments, have a max dimension of 0.5m x 0.5m x 0.5m, and a combination of wood with another material is required in the build.

This project was a collaborative effort with Alastair Lascelle, Emmett Mack, and Nicholas Onea. My role in the process involved working on the wood components of the stool and I also coordinated tasks and guided next steps for my team members. 

individual concepts
To initiate the design process, we each developed our own designs and combined aspects from each of them to end our finalize the concept that we continue with. 


FINAL DESIGN ORTHOS



material analysis
After evaluating the different materials and finishes for this project, we prioritized durability and weather resistance to ensure the stool could withstand outdoor conditions. 

We chose to use Western Red Cedar for its natural resistance to rot and its oil content, which helps prevent bacterial growth. To further protect the wood from the elements, we applied a polyurethane finish. For the metal components, we opted to sandblast the steel tubes, as this finish enhances durability and allows for easy restoration if damaged by weather conditions.




components of final design


manufacturing

base The base was made by cutting boards to size on the mitre saw and glueing them together in layers. Then it was cut into a rough circle on the band saw and then edges sanded smooth. Three of these were made to make up the base. 

bad things happen.



 the problem We originally planned to make a single cut across the base to create two separate components using the band saw. After realizing that the workpieces wouldn’t fit under the band saw when the bed was tilted at an angle, we used a hand saw as a last resort.  
After completing the cuts, we then discovered that our initial measurements were incorrect and that we would have to make adjustments to our design to accomodate the mistake.  
With a lot of sanding, we were able to recover from the error. 

design change After rearranging our cut pieces, we found an orientation that not only worked, but was also more visually complex and interesting. This was our happy accident. 




grooving The grooves in the base for the legs were measured onto the base and then cut out using a pluge-base router. Multiple passes were done to create the perfect width and depth for the legs to sit in. 

metal working
As our first time working with welding, the first (couple) attempst at getting tubes welded to the plate required multiple tries to align with the wooden base. Each time, legs weren’t perpendicular the to sheet metal that would be attached to the bottom of the seat, which was crucial for the design to work. Repeatedly welding in the same spot caused the plate to warp significantly. We resolved this by starting from scratch with a thicker, 11-gauge plate, which held up much better through welding. 
ATMPT 1
ATMPT 2

the seatConstruction of the seat started with planing and gluing planks side by side to cut the circular shape from it. The backing of the seat was cut from scraps of wood and glued in plavce to be routed and finally sanded smooth. We also made a lip onthe bottom side which would make the metal plate invisible. 


finishing
Finals steps were to sand everything smooth, finish with polyurethane, drilling holes in steel plate to insert screws, sandblasting the steel legs, and finally assembling everything together. The base is friction fit to the legs and the steel plate is screwed into the bottom of the seat. 

findings and challenges
This project was a valuable learning experience for me as it was my first major group project. Collaborating to combine our ideas into a final design allowed everyone to contribute to the outcome. Although we faced challenges while building our prototype, adapting our plans strengthened the final design and helped us develop problem solving skills at a pount where we felt stuck. The project also gave me the opportunity to explore new fabrication processes, including tube bending, sandblasting, welding, and routing.