PackFlatToolFreeAssembled Furniture Line
Wedgewood Furniture’s Beat Line was designed to be eco-friendly from start to finish. We wanted to produce a line of furniture made from sustainably harvested or recycled materials, produced with minimal waste, finished with non toxic finishes, packed flat in recycleable boxes, shipped flat and designed to be easily assembled and disassembled by the consumer. Details evoke a musical cascade, and add an intriguing visual element to the designs.
UNIQUE PROPERTIES / PROJECT DESCRIPTION:
A patented assembly system is behind each simple, sturdy, and comfortable piece of Wedgewood Furniture—no metal fasteners or screws are necessary. What’s more, assembly is quick and intuitive. Chairs use integral hooks that are held tight using tabs and wedges. Tables employ pairs of complimentary grooves held tight with a wedge. The beauty of the Wedgewood System is that it allows for pack flat shipping with easy assembly and easy disassembly for occasional or seasonal storage.
OPERATION / FLOW / INTERACTION:
Wedgewood Furniture’s Beat Line is machined from bamboo plywood or Valchromat fiberboard on a CNC router. This results in the very tight tolerances and repeatability necessary to insure a precise fit. Beat Line Furniture is packed flat for shipping, and can be assembled in minutes. Additionally, it can be taken apart in minutes for transport or seasonal storage. The Wedgewood Assembly System is the simplest strongest method available for constructing pack-flat tool-free assembled furniture.
PROJECT DURATION AND LOCATION:
The project start in April 2012 in Mexico City
FITS BEST INTO CATEGORY:
Furniture, Decorative Items and Homeware Design
PRODUCTION / REALIZATION TECHNOLOGY:
CNC machining requires flat sheet stock. We chose 25mm bamboo plywood for its beauty, strength and durability. We also found a through colored fiberboard material called Valchromat. Both materials are weather resistant when properly finished and are sustainably produced. CNC machining allows us to make consistently fitting pieces and create elaborate decorative patterns easily. An added benefit of CNC manufacturing is the interchangeability of parts in the event that a component gets damaged.
SPECIFICATIONS / TECHNICAL PROPERTIES:
LoungeChair: 800mmx600mmx800mm Box:950mmx780mmx150mm
Cocktail Table:1219mmx762mmx457mm Box:1380mmx980mmx90mm
Side Table:457mmx457mmx457mm Box:600mmx600mmx110mm
Flat Pack furniture, tool free assembly, Bamboo plywood, valchromat, ecofriendly, sustainably harvested materials, assemble in minutes, patented system
A traditional trestle table and benches were the starting point for the Wedgewood Assembly System concept. Then there was a need for chairs. Based on the premise that all the pieces should pack flat and use no metal fasteners, a design concept emerged using integral hooks, pierced tabs and wedges. Then, in a true cocktail napkin moment, a system of interlocking grooves was conceived for tabletop attachment. Using this system, an entire line of furniture could be created.
The system that evolved for our line of furniture came from hours of thinking about how to hold flat planar pieces together using just pierced tabs, wedges and interlocking grooves. Important too was that table legs not pass through tabletops and that pieces could be taken apart. The components had to be able to be machined using a CNC router with minimal human handwork. As there isn’t a source of information to meet our goal, the solutions came out of many hours of head scratching and doodling.
TEAM MEMBERS (3) :
Diego Arevalo Pliego, Gifford W. Cochran and Erick Balderas
All photos by:
Diego Arevalo Pliego
Ximena Arevalo Pliego
Patent No. US0704,467S Gifford W. Cochran 2014 USA
Pending Patent US 14714147 Gifford W. Cochran 2015 USA
Pending Patent MX/a/2014/016004 GWC Design Inc S de RL de CV