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Design of a CNC Routed Sheet Good Chair %A WY.7

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Design of a CNC Routed Sheet Good Chair %A WY.7 Design of a CNC Routed Sheet Good Chair MASSACHUSETTS INSTITUTE OF TECHNWOLOGY by SEP 17 2O10 Noel R. Davis Submitted to the Department of Architecture LIBRARIES in Partial Fulfillment of the Requirements of the Degree of ARCHIVES Bachelor of Science in Art and Design - Architectural Design at the Massachusetts Institute of Technology June 2006 @2006 Noel R. Davis. All rights reserved. The author hereby grants to MIT the permission to reproduce and to distribute publicly paper and electronic copies of this thesis document in whole or in part in any medium now known of hereafter created. Signature of Author: \o rDepartment of Architecture May 19,2006 Certified by: %AWY.7 Shun Kanda Senior Lecturer in Architecture Thesis Supervisor Accepted by: s \a Wahap r Professor of Architecture Director of the Undergraduate Architecture Program 1 Design of a CNC Routed Sheet Good Chair by Noel R. Davis Submitted to the Department of Architecture on May 19, 2006 in Partial Fulfillment of the Requirements for the Degree of Bachelor of Science in Art and Design - Architectural Design ABSTRACT A chair of acceptable comfort, requiring minimum material and labor, was made by de- veloping a system of parts and joinery, cut from sheet stock, using only one tool-a 3-axis computer numerically controlled router. Comfort is achieved through ergonomic shaping of the chair components to embrace the geometry of the human body, and support several comfortable seating positions. All components were cut with a 3-axis CNC router using only one cutting bit. The joinery requires no additional hardware, glue or fasteners to hold the chair together. The final chair design requires 12.5 square feet of 1/2" sheet stock. Cutting time on the router is 1.5 hours, and assembly, which requires only a mallet, takes 0.5 hours, giv- ing a total production time of 2 hours. Using Baltic Birch Plywood, the total material cost is $16.00. Using Oriented Strand Board, the total material cost is $2.88. Thesis Supervisor: Shun Kanda Title: Senior Lecturer in Architecture 2 Thesis Committee Shun Kanda, Senior Lecturer in Architecture, MIT Thesis Advisor John Ochsendorf, Assistant Professor of Building Technology, MIT Thesis Reader Christopher Dewart, Technical Instructor in Architecture, MIT Thesis Reader 3 4 Introduction: The impetus for this thesis came from a desire to work with design and construction at full scale. While con- structing buildings at full-scale for an undergraduate thesis would be impractical, the design and construction of furniture incorporates many of the same principals as architectural design, and full-scale construction is not only possible, but gives the opportunity for users to experience the design as built rather than purely in models and drawings. Many well known architects have designed furniture throughout the last two centuries, and in some cases their furniture pieces have become icons of design. Architects like Frank Lloyd Wright, Mies van der Rohe and Alvar Aalto designed chairs that not only enhanced and completed their architectural works, but remain as well recognized as many of the buildings they were designed for. The design of chairs-defined in this study as a devices for sitting and resting the back, differentiating them from stools, which have no back rest-has been attempted by countless designers and craftsman over thou- sands of years. In order to give relevance to this particular investigation, it was necessary to first establish a set of goals and constraints to inform the design. For this thesis the use of a single tool, a 3-axis CNC Router, with a single bit was permitted to produce the components of the chair. The chair was to be made from a minimum amount of material. A product of the previous limitations was the necessity to incorporate the joinery of the chair into its components so that con- nection hardware would not be necessary in the design. Critical to any successful chair is the comfort of the user, which could not be ignored in the development of this design. Finally, as a reaction to global economic and environmental issues, the design would also address the reduction of cost and environmental impact. 5 Process: Following the criteria set forth in the thesis statement, an investigation encom- passing the design and development, to varying stages of completion, of eight chairs was carried out. The final iteration is presented as the completed product %*New of the thesis, and the piece on which the success of the investigation should be judged. 1~-~.--~ 'i Chair 1: The first design iteration, called from here forth Chair 1, displays a timid use of the CNC router as the main tool. The router is used to cut foam formwork, around which, 1/8" plywood sheets are bent and laminated with glue to form the outer "shell" of the chair. The flat seat portion is cut from 1/2" plywood on the router and glued into place within the shell. This shell serves as the structure as well as the back support of the chair. The method of connection, or joinery, in Chair 1 is strictly glue-strength and the chair uses two sheets of 1/8" plywood for the shell and 1/4 sheet of 1/2" plywood for the seat. The form of Chair 1 is inspired by Frank Lloyd Wright's Barrel Chair (Eaton 1997). Chair 2: Chair 2, the second design, uses a cantilevered structure to support the seat off the ground. Again, the router is used only for cutting foam formwork, and the method of connection is glue-lamination. The base of the chair, which supports B the main bent-wood component, is not defined completely and has been modeled as a solid mass with a slot to hold the wood seat. Chair 2 requires 1 sheet of e 4. 1/8" plywood for the seat and an unknown amount of wood, metal or masonry to form the base. The structural form of Chair 2 comes from the precedent of Marcel Breuer's Cesca Chair [Wilk 1981]. Chair 3: In Chair 3 the capabilities of the router to cut plywood and form integral joinery were investigated. A dado joint, common in traditional wood joinery, is made by cutting only part way into the plywood with the router, creating a slot. This slot was cut to receive, with glue for strength, the edge of another component of the chair. While Chair 3 uses the router more effectively than earlier designs, it also reveals a limitation of the router, its ability to cut dados only at 90 degrees to the material's surface. Without using an angled bit or a 4-axis router, this diver- gence from 90 degrees can not be created, and as a result the joinery in Chair 3 does not fit exactly and relies heavily on glue strength. Rather than introduce new or more complicated tools it was decided, for future designs, to use the dado joint only in the applications where it could be cut accurately by the router. Chair 3 was built in model, but never at full scale, due to its joint inaccuracy. At full scale it would use 1 sheet of 1/4" plywood for the structural frame, seat and back. The form of Chair 3 is based on a number of designs of 3-legged chairs, including my own (Noel Davis') 3-legged Ash Chair. 7 . ........... Chair 4: Chair 4 was designed in two steps, first the seat and then the leg and arm as- sembly. The seat is constructed using the dado joint within the router's 90 de- gree constraint, and a new joint, the half-lap. The half-lap joint, common in tra- ditional wood joinery, creates a recess in two pieces of wood, which overlap at these areas. The half-lap joint relies heavily on glue for its strength, but helps to secure the accuracy of positioning between pieces. The back of Chair 4 has two laminated rails, each made of two 1/2" thick pieces glued together, which use dados to hold sheets of 1/4" plywood in a curved shaped. These 1/4" sheets form the seat and back of the chair. The laminated rails are joined to each other by four slats, which are connected with half-lap joints. The seat of Chair 4 is shaped ergonomically, following the contour of Charles Eames' Aluminum Group Office Chair (Drexler 1973). The leg and arm system of Chair 4 demonstrates the first iteration of a mortice and tenon joint, adopted from traditional wood joinery. In this case the tenon, a rectangular peg cut into the end of a member, fits into the mortice, a rectangu- lar hole cut into the side of a member. The friction between the surfaces of the mortice and tenon provides a most of the joint's strength. Additionally, glue on these surfaces increases the strength of the joint. The structural system of the legs for Chair 4 builds on the design of Mies van der Rohe's Brno Chair [Glaeser 1977). Chair 4, requires 1 sheet of 1/2" plywood for the legs, arms and seat frame, and 1/3 sheet of 1/4" plywood for the curved seat and back surfaces. 8 ............ ..................................... :::::....................................... ................ Chair 5: In Chair 5, two significant changes came about, informing the final direction of the study. First, a time-tested four-legged design for the chair is adopted, shirking N0 the notion that a useful and well-designed chair must stand on a unique struc- tural system. Second, the use of a series of small, repeated elements allows for contouring of the seat to fit the curves of the body, as well as provided a more ef- tir - ficient use of wood.
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