R Credenza

For a little over a year now, I've been chasing around some concepts about flat-pack design: its history, its widespread adoption, and design research into modern methods. Parallel to these explorations, I've been using a CNC router and digital file hosting to test out new methods of manufacturing. My first product, the Zip TIe Lounge Chair, went live on OpenDesk last May. Made from a half-sheet of plywood and 44 zip ties, it uses common industrial materials and a universal design language that can be digitally distributed and modified. It was my first open-source object. I was optimistic about its possibilities, imagining a future where Amazon would CNC furniture right in its distribution warehouses for same-day delivery.

I was lucky enough to have it crop up on a few design blogs and featured in Make magazine. Released for free under a Creative Commons license, it has accumulated 2,000 downloads over 10 months. Via social media, I found that at least two people have built one, in Barcelona and Ohio (both using makerspaces). The miserable download-to-build ratio (.09%) illustrates the trouble with truly open-source, digitally fabricated furniture: it's still a lot of work, using machines that are not widely accessible. The chair looked too severe, shaped by the machining method and material constraints. More than a few commenters took issue with the durability and aesthetic of the zip-tie fastening. Six weeks in a gallery show proved their point, as UV light and lots of sitters broke the ties across the front of the seat.

William HolmanMarch 1, 2015flat-pack, flat pack, r credenza, ratchet strap, zip tie chair, fab labComment

Flat-Pack Design: Methods and Materials

IKEA's vast particleboard empire is built on one prime directive: affordability. Each product in their 10,000-item catalog starts with a price point and then backs into materials, colors, ergonomics, structure, and fastening systems. A key part of the cost strategy involves flat-pack, ready-to-assemble designs that are up to seven times more space-efficient to ship than conventional furniture. All of this tweaking and tinkering is done by a crew of 16 in-house designers and about 100 freelancers (a crew that is always looking for pitches!). The process is intense, taking up to five years, and involves close coordination with sawmills, manufacturers, distribution warehouses, and focus groups.

It would seem, then, that IKEA would be the authority on flat-pack design. Yet people hate putting together their furniture, generating memes in equal proportion to wobbly bookcases the world over. Frustration seems to cluster around two things: language-agnostic instructions made up of impenetrable diagrams, and fickle fasteners that never seem to equal the holes meant to accept them. That said, from an engineering view IKEA's hardware is ingenious, combining simple tools with self-registering systems that (hopefully) force pieces into alignment as they are assembled.

William HolmanJanuary 30, 2014IKEA, flat pack, ready to assemble, hardware, fasteners Comment

Flat-Pack Design: Past, Present, and Future

Twice in the last few months I have been out to FabLab Baltimore, at CCBC Catonsville. Last week, I took the introductory workshop that is a prerequisite for using the facility. At home, I've been hard at work on the CAD files that will translate my Ziptie Lounger into some form that a CNC router will understand. All of this is in preparation for prototyping my first machine-made piece of furniture, which I've posted over at OpenDesk, a platform for distributed design. Distributed design, in its simplest form, operates something like Instructables -- a central online repository of DIY manuals that folks can follow to make their own products. However, making something from scratch still presents significant barriers to entry, namely skills, tools, and time.

OpenDesk, along with similar startup Assmbly, are challenging (or, to use a current term of art, "disrupt") the traditional design-manufacture-wholesale-retail model that the furniture business has operated on for a hundred years. Designs are uploaded to the OpenDesk site, where they can be downloaded directly for free or, for a fee, sent to a local networked fabber who will cut, sand, and drop-ship the parts to the consumer's doorstep. Everyone in the chain -- OpenDesk, designer, and fabber -- make a small profit. Due to the nature of both the fabrication machines and the distribution network, all of the products are flat-pack.