Chair Project Jozy Klupar
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Material Manipulation
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I began pulling inspiration from the idea of manipulating materials in a way that pushed their limitations. I was intrigued by materials that simulate characteristics of another material.
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Sketch Development My initial concept played around with laser cut sheet metal that was meant to simulate lace. From there I played with the idea of manipulating the sheet metal so it would appear to act the same way fabric would.
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I was intrigued by simulating fabric, so I began sketching flowy fabrics draped over chairs. I then dove into options for materials and chose something as far away from fabric as possible.
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Final concept The idea is that this metal sheet can have any laser cut pattern, be any color, and be interchangeable with different frames. The base would be consistent in form but could vary in materials, possibly for special edition chairs.
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The metal sheet can also vary in exposure of the frame depending upon the size of the sheet. I wanted the frame to just be a small simple structure where the metal fabric can “hang�off of.
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Mockups I began with scale models and quickly moved into full size. I built a full size frame and used paper as the the “fabric�. It helped me get an appropriate size but was not close enough to the actual material.
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Orthographics: Frame All Dimensions are in Inches. Material: 181� Aluminium square tubing
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Metal Fabric: Pre-bent
56”
22”
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Metal Fabric All Dimensions are in Inches. Material: 18 gauge steel sheet metal
20.0 6.0
15.0 15.0 24.0
2.0
4.0 R
.25 R
0.25
20.5 34.5
38.0 14.0
.25 R 22.0 25.5
2.5
5.0
4.5 .25 R
20.5
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Section view: part two
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Fastening The pieces would be fastened by welds in three places. They could be welded underneath the metal fabric piece. This would not be aesthetically disrupting because it would not be seen from the top of the sheet metal.
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Possible Processes High Volume
Waterjet cut or laser Stamping with few secondary processes; press break/roll bend
Low Volume
Waterjet cut or laser Press breaking, Roll bending
Secondary process for both
+ Metal edges are sanded + Pieces are welded together Materials: + Perforated 18 gauge 22� x 56’ steel metal sheet + 181 inches of square aluminium tubing
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Prototyping storyboard
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Cut the square steel tubing into 10 pieces. Then weld the pieces together, starting with the back of the chair, moving to the seat then welding those together.
Next, weld the legs onto the body.
Then clean up the welds by sanding or grinding so they look flush. 15
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Buy a Tech Shop membership then use their water jet cutter to cut the piece and lace pattern out of the sheet metal.
56�
22�
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Press break the seat crease and the two spots where the chair will force fit together. Then press break the side, but not as sharp an angle as the other two.
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Roll bend the seat back and seat pan. Then roll bend the front, the side and lastly the top.
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Sand the edges.
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Paint both pieces.
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Making It!
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Weld it There was 182� of square tubing, cut and Tig welded together in 8 places.
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Grind it Once I had the parts welded, the welds needed to be ground down to look flush.
Brush it
I wanted the frame to have a brushed finish so I took a L bracket and piece of metal with sandpaper and permiceled them together.Then I moved the piece back and forth.
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Making It!
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Make the File
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I made a file in Illustrator and saved it as a DXF file. Then I had to adjust the pattern in FlowPath. and tell the machine the path I wanted it to cut.
Bend it
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Waterjet cut it
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Fasten it
Once I had the file made in FlowPath I had to save it as a OFD file and then open it in FlowCut with the machine. It slowly cut all the parts out using water and abrasive.
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I then roll bent the metal in some places and hand bent it in the more difficult areas.
I used blind threaded inserts and drilled a hole in the metal frame and inserted the piece. Then I put bolts in the holes in the sheet metal and threaded them into the inserts.
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Thanks to the
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