GCSE Resistant Materials‘A’ GradeTask: 11-Coffee Table

Contents10.Final Specification 11.Initial Designs

12.Development  13.Final Design Proposal 14.Modelling and Testing 15.Evidence of CAD/CAM 16.Cutting List 17.Plan of Making – flow chart 18.Manufacturing Diary 19.Evaluation

1.Context and Design Brief  2.Analysis of Context  3.Research into Existing Products 4.Product Analysis of PRIMARY Research 5.Materials and their properties 6.Materials and Finishes Testing 7.Other relevant research  8.User Profile 9.Analysis of Research 

 

I am going to design and make a Modern style coffee table that is suitable for the first time buyer. It will be suitable to put in a flat as most first time home owners live in flats or apartments. It will be able to store various things. It will be multipurpose. The coffee table will be designed for IKEA the high street retailer and it will be sold their. My product will be suitable for batch production. I will use materials that have been used before to make my projects more environmentally friendly.

Design Brief

Context 11A major high street retailer wishes to market a multipurpose, modern style small coffee table aimed at the first time buyer. The product could include some storage space. Design and make a coffee table for this market.

Analysis of contextWhat will the product need to store/how will it function?The product I am designing will have to have some storage facilities, also it will have to be able to be used as a coffee table that is suitable for multipurpose jobs. Indents in the table will stop any mugs/cups from sliding around the table, also a drawer underneath that will be able to store magazines.

What environment will the product be designed for and how will this affect the overall design?The product is aimed at the first time buyer so they will be most likely to be living in a flat of apartment. The coffee table will be suitable for different rooms whilst still being used as a regular coffee table. This means that my product would have to have certain components eg, feet so that the surface isn't scratched. A flat surface is also needed so that any coffee cups don’t slide off a spill. The legs must be the same length so that the table doesn’t rock and anything on it fall of or over.

What materials will the product be made from and how can you consider environment issues when selecting these?My product will have to be made from materials that aren't easily scratched. Also the materials will have to look good as it may be stored in a living area. I the materials I choose must be Semi-Permeable so that if something is spilt on it the liquid wont be absorbed and it can be wiped off easily. I will use materials that can be recycled so that I am contributing towards a better environment.

How will you assemble the materials?My coffee table will be assembled using Mortise and Tenon joints to attach my table legs to the table top. I will use this as it is easy to do and will give a good finish as it is not easily noticeable. I will use various components also on my table so that it will be fitted together well. I will have to use Adhesives, nuts and bolts so I can put my various materials together.

How will you ensure your product is suitable for commercial production?I will use CAD/CAM to produce most of my product so that is it was commercially produced it would be easy to assemble. This would also make the product more accurate and look professional.

Are their any cost restrictions that will influence your design and why?The product will be restricted by cost as it will be designed with IKEA in mind; which limits the cost due to furniture being sold at affordable prices. This means I cant spend to much on it as I wouldn’t get as much as I profit that I could.

What sort of shop/retail outlet could you see your product being sold in?I could see my product being sold in a highly renown retail store like IKEA. This is because it is the type of multi-purpose item that could be sold their. Also it would have a good quality finish and a good appearance, this is because it will be mostly designed and made using CAD/Cam.

Existing ProductsI have chosen this product as I think the design is unique and I would like to interpret something like this into my design.

In this product the legs are made from wood and the table top from glass, they may have used glass on this as it can be recycled after use, but on the other hand the glass will have to be melted at a higher temperature than plastic so it will be worse., I would like to use these same material choices but I am not able to use glass on my product.

This product doesn’t have any type of finish but will have wood protection on it, on my product I want to use a finish on it to brighten the product and make it stand out more.

This product will have be made using CAD/CAM as it is the cheapest and easiest way to make it, my product will be mainly made using CAD/CAM with some hand skills included.

My personal opinion on this product is that I like the unique design and it would fit in well int. a household, this is because no colour scheme is really present in this product.

I like this product as it is a simple design but still looks good. This would be a good design as it is easy to make using CAD/CAM.

This product has a plain black colour scheme , I am thinking about using a dark colour on my product so that other colours would stand out more and it would make it look more aesthetically pleasing.

This product will have been made using CAD/CAM as it has a simple design.

This product will have been made using some sort of plywood as this is one of the only woods that could bend and still be strong enough to hold weight and not break.

This product will have been made using CAD/CAM and some hand skills used to fully assemble the product.

This coffee table has a wooden plank fitted under the main table, this can be used to place magazines and other items could also be stored there.

This table has been made using wood and will have be coated with a wood protective paint on it.

I like this product as it is had a traditional look. Also the pattern that has been engraved on the table top.

This is a bench but I thought I would be able incorporate this design into my coffee table. I liked design of having a table top and wood around the edges and then I could place a drawer underneath to store items in it. This product has been designed so that it

is good for the environment, this means that when built I will not have been made all be machines and all materials with be fully recyclable so that when it isn't needed anymore you can recycle it and look after the environment.

This product will be made from fully recycled wood. This means that the bench will not have had a large environmental impact when getting the materials to make the bench.

As this product will be used outside the wood will have been treated to make it waterproof but other than that to reduce the impact on environment no other refinishes will have been used.

Existing Products

This table has a simple but smart design. Where the legs join the table to holes have been cut into the table top so that you can put mugs in.

This table is using black as a single block. This colour choice makes it able to be put in any room as the colour black will go with any colour you want It too.

This table will be made with metal and will have been produced on a production line by machines. The reason for this choice is that it will be cheaper, easier and faster to make than if you had people doing it.

This table has a unique style with only using three legs unlike most tables with have 4. The edges are all curved off to give it a better look.

These children's tables have been designed with a target audience in mind. This gave them a clear indication of what they would have to look like.

The table tops have been finished with bright, bold colours to make them more appealing to children. No sharp edges are present, this prevents any injuries as small children will be using them.

There is a basic shape of the table with four stable legs to prevent collapse’s, the wood will also have had a finish that will make it more water resistant to the table isn't damaged

I chose to use this table as I think I may be able to bring some if its design into my own. The small glass ledge under the table top will be useful for putting things on e.g. Magazines.

I am not able to use glass in my product but I would be able to replace the glass with acrylic plastic and it would still work.

This table will have been made using machines and a work force, this is due to the glass, machines would no be able to place the glass on the metal legs.

I have chose to include this image as it has similar aspects as I want my design to have. I would like to include the small desk underneath the table top.

This table has been made of a man made board with sheets of wood glued around the main board. They are held up buy tubes of plastic that have been glued to each panel of wood.

Not many finishes have been place on this item of furniture as it does not need anything to be added to it. Think sheets of plastic have been placed on the edges.

When manufacturing this they would have taken into account the affects it would have on the environment. The glass if better for the environment than plastic as it can be recycled where as plastic cant, but they would have to burn more fuels to get a higher temperature to melt the glass down which I higher than plastic.

Research into existing Materials

Pine woodI have chosen pine wood as a material I could use as it is a natural wood and is better for the environment than man made wood are. Pine wood is relatively cheap so I can use it for my table. Pine is easy to cut and shape, this would make my job easier and save time meaning I can concentrate on getting a better overall grade rather than just getting the shape I want. Pine is an easy wood to get a nice smooth finish on.

Maple wood

I have chosen maple as a material I could use as it is another natural wood making my table better for the environment. Maple is hard and strong this means that it wont be scratched easily. Maple is relatively easy to cut making my job easier giving me more time to do other things. Maple can have a good finish if done correctly, this will make my project look better. I could use this for the legs ion my design as it will have a good finish due to its smooth consistency.

Polyvinyl chloride (PVC)

I have chosen PVC as a material I can use because it is easy to shape and is available in a variety of different colours. At the end of my tables life cycle I can recycle PVC making my project better for the environment. With PVC is heated it can be bent into any shape so I could use it for many different uses. If were to mass produce my project I could use this as it is easy to shape and easy to cut speeding up my product time which saves money.

Acrylic

I have decided to use acrylic plastic on my product as it is easy to make by designing the shape on the computer and using the laser cutter to cut it out. I also think that if I use light gathering acrylic it will give my product a different aspect to it. I could also use this for my table top as it is waterproof and easy to clean.

GlassI could use glass on my project as a table top, I would use it for this purpose as it is impermeable so it is waterproof. Also after someone was finished with the table they could recycle the glass making my table better for the environment. Additionally I would not have to apply any finish on the glass I would only have to clean it. If made in industry glass will probably be used for the top, however we do not have the facilities to cut glass in school.

Finishes and components Research

Varnish: I would use varnish on my product as it is waterproof. Also if I decide to make my product out of natural timber it enhances the grain and gives it a good finish lifting all grains to improve the appearance.

Gloss: I would use gloss paint on my table as it gives it a good finish. Gloss paint can be washed easily as, also it is waterproof and any spills will be easy to clean up.

Bee’s Wax: I would use bee’s wax as it would give my wood a good finish. When bee's wax is applied it lifts the grain bringing the colours out. I think I would prefer using the varnish as it does have a colour added to it which would also enhance the grain.

Runners: I would use runners on my table because if I have a drawer under it I would nee to be able to slide lit out. This would be good for my project as It would as another element on my work. If I was to mass product my project it would be hard to use these as a machine wouldn’t be able to fit these.

I will use adhesive glue to glue my different materials together as this is easy to use, fast drying and very strong. The only problem is it’s not recyclable as it’s a thermosetting plastic. I have chose to use this as it will be the best type of glue to use on wood and plastic.

Ergonomics and Anthropometrics Under my desk I want to

have somewhere to put magazines. I need to add something so the magazines don’t slide around. For this I need to get the dimensions of magazines.

210.82mm

Depth: 7.62mmHeight: 274.32mmDiameter: 210.82mm

In my desk I will put I a little indent for the mug to go in so it doesn’t slide on the table. I will have to make it so that it will fit almost any size mug.

95

.25

mm

82.55mm

Height: 95.25mmDiameter: 82.55mm

1539.74mm

Depth: 1539.74mmHeight:449.83mmDiameter: 1539.74mm

Here I have found measurements for a few tables and was able to get a suitable size for my project. I have had to make my work to a certain size so that it fits into the area.

Ergonomics

Ergonomics is about people and how they fit into the items they have around them, e.g. used to make items like chair so that they fit to the human body.

Anthropometrics

Anthropometrics is the human body and how it works within the environment around it, e.g. measurements of how to fit into the a chair.

27

4.3

2m

m4

49

.83

mm

User ProfileName: Joseph James

Age: 21Occupation: DesignerInterests: Creating new designs and ideas, socialising and meting new people in the area.Location: Manchester, EnglandThoughts: Original design, looks good in a household area. Table needs to be larger to get better use out of it. Limitations: The table has a specific colour theme so it wont fit into some rooms if the colour scheme is not the same.Cost: £30-£40

Name: Wajeeha QaziAge: 25Occupation: Designer/artistInterests: Finding new inspiration for me to paint, going out with friends in the local area.Location: Liverpool, EnglandThoughts: A smart design that enables me to use the table for all purposes needed.Limitations: The table is not large enough for me to use effectively as I cannot fit enough things onto the table top.Cost: £35-£45

Name: Frank HollowayAge: 42Occupation: MusicianInterests: Playing different musical instruments Location: Warrington, EnglandThoughts: A unique design that has a smart colour scheme.Limitations: The table top needs increasing in size to get the maximum use. The rest of the table also needs increasing in size so that it is taller.Cost: £25-£40

Analysis of ResearchIn my research into existing products if found that tables can cost from about £30-£200. Tables are made from different materials but most are wood, plastic or glass. Certain tables are ready made so they cant be disassembled but the cheaper ones you normally have to put together yourself. Most tables have plastic or some material on the bottom to stop them from scratching the floor. Most coffee table will have four legs but some of the more artistic ones will have three. They have drawer under the table to prevent the table being clustered with magazines and other items. I will consider this when designing my table and make sure my table included these popular findings.

Whilst researching into existing materials I found that there are lots of different materials I could use to make my project successful. I researched materials that I will be able to use and that will look good when I am finished. I found that the best material for me to use on my project would be flexible plywood as I will be able to make it into any shape I would want and it will still have a good visual affect.

On this slide I have researched into ergonomics and anthropometrics, I did this research so that it would give me further help into how I will have to make my design. I found the average sizes of tables on the market today, the size I will have to make my drawer to fit the magazines and the size hole I will have to make to fit in a mug. I gave a brief description of what ergonomics and anthropometrics are also. I will make sure that my table considers these measurements to ensure all items fit neatly on the table.

On this slide I researched into some finishes and components that I could use for my project. I found that I would be best using varnish on my project as it has a good finish and Is waterproof and also gives the wood a little shine. I also found that if I want my wood to have a good natural colour on it I should rub bees wax into it as it brings the grain out of the wood. Either of these will do, although I think the varnish will stand out more giving it a shiny appearance.

SpecificationMy design must: Reason:Have a target audience from the age of 20-45. To give my item a large area to sell in. I chose this age range as these are the main people that are buying

new homes and looking to furnish them.

Have a place to store items To store items in so that the table doesn’t get filled with junk. This will also add an extra aspect to my project. To do this I will add a draw or a shelf to place items on.

Not include any offensive language or images. So that my item isn’t offensive to any religions or anyone else. Also I may not be able to make my project. To make sure this doesn’t happen I will research into things that may be found offensive and not include them in project.

Be a suitable size So that it will fit into a house and be at the correct size for the proper use. 449.0mm in height, 153.9mm in depth and 153.9mm in diameter, I found that this would be a suitable size for my coffee table to be.

Have a consistent house style So that my item will have a good chance of selling and it wont look out of place. Also if it doesn’t have a consistent colour it won't look right.

Be suitable to its environment So that it wont look out of place and will fit properly indoors. Also if I put my item outdoors it will have to be waterproofed. Additionally even if it is kept indoors my table top will have to be waterproof so that if anything is spilled it wont be absorbed.

Have a low cost So that I will be able to afford to make so that I am not restricted when making my product. Also if I am to sell my item the cost to make will be have to be as low as possible so that I can make more profit of it when selling.

Be waterproof So that if anything is spilled it would be absorbed. Also if it is moved outdoors and it rains the product wont be completely ruined. I could do this by using plastic or if I use wood add a waterproof finish.

Have holes to place glasses/mugs in So that they wont slide around on the table. This will also help to prevent spillages on the table. I will cut these out using the laser cutter.

Use suitable Materials For my table top I will use acrylic as it is already impermeable and for my legs I will use Plywood or MDF as it is more stable than plastic and also cheaper when using to make.

Have a finish I won’t have to finish my acrylic apart from cleaning it, I will use varnish on my wood legs so that is becomes more waterproof and the aesthetics is improved by enhancing the grain.

Initial IdeasTo make this design I followed the design specification so that it will have everything that is needed. It has the basic table top that will be made of MDF as it is easy to shape and after sanded down it will have a nice finish. On the corners I will use finger joints as these will be the easiest to make using CAD/CAM. In these joints I will use PVA glue to make the hold stronger, this will prevent the pieces from being taken apart. I will put a wood protector finish on it so that if anything is spilt on it the surface of the table will not be damaged. This will also give my wood a darker colour improving the aesthetics. To make my design I will use a mixture of CAD/CAM and hand work so that it will have the best possible appearance, using CAD/CAM will also speed up production time and make the cuts more accurate than I could do by hand. For the base of my design I will also use MDF as it is the easiest wood to work with and it has a low cost, I will also add small feet to the bottom with a layer of fabric to prevent the base from scratching the floor. A bad point about this design is that it is a quite simple design that some people may not want to buy as it would not stand out in a home. A good point about this design is that as it doesn’t have a specific colour scheme so it would fit into most areas of a home.

This design is my favourite one as it has a unique style to the rest and looks the best. This design needs some more components to it so that it will meet my specification, I will add a acrylic table top that will rest on the supports to make the project more suitable another reason for me to use acrylic is that I wont need to add any type of finish to it, I will then add more plastic in-between each support so that I could use the below bit as an area that I could store items in. I will make this out of a mixture of wood and plastics as this is the easiest way for me to make each part more accurate. The table top and its supports will be made out of acrylic plastic as it will be able to design them and cut them out using the laser cutter, this will make my pieces more accurate and they will have a better fit. I will make the legs out of wood as this will be the most supportive thing to use if too many items are on the table it wont collapse, also I will be able to cut these out using the router making each piece identical. I will use cross halving joint to fit all of the acrylic supports together as this is the most stable and least complicated I will then add some tensol glue to make the hold stronger. I will use the same type of joint cross halving joint on the legs but not as complex as there aren't as many pieces to slot in, here I will add PVA glue to again make the hold stronger. To attach the acrylic top to the wooden bottom I will use araldite glue.

I developed this design by looking at my specification and seeing what I needed to include too make my product successful. From here I added different aspects to it as I went on to make sure that everything was covered. I would create this design completely out of MDF as it would be the easiest to work with, I will be able to cut each side on the router to make them accurate. I would then be able to add wood protector to give my wood a darker tint giving it a better look and help protect against spillages. I would use finger joints on the corners to get the best possible fit and so that it is strong I would then add PVA glue to them to make them stronger this will also prevent the pieces to be taken apart. I don’t particularly like this design as it is too plain without many different components to it. On this I would have a flat base with two shelves cut out of the sides. I would then add small feet to the bottom with felt on the bottom of the feet to prevent the floor from being scratched. It would have two holes cut out go the table top to place mugs into to ensure they don’t slide around and spill, I will make these by including them in on my design on the computer and then when I use the router to cut it out it will be done for me I will then sand these down to remove the sharp edges.

This design is the hardest out of them all for me to make as it has six draws and a shelf on it, this would include too many things to do in the amount of time allocated. I also wouldn't be able to make this as it would include too many components for me to buy and I wouldn’t be able to afford it. I would again make this all out of wood as it would be too hard to use any plastic on this, also wood is more suitable for this as it is stronger plus you could add a finish to wood to make it look better e.g. Bee’s wax. This design meets most of the specification, the problem with this is that it has a common design therefore people would rather buy a different design. I would use finger joints on the corners again to give it the best possible fit, this would be the strongest one to use of the lot ,I will be able to make these fit perfectly buy designing the woods shape on the computer and using the router to cut it out. In the finger joints I would include a drop of PVC glue to make the fit even stronger and make it so the woods cant be taken apart.

Whilst I was drawing this design I made sure it was slightly different from the rest. I did this as some of them where too similar and I didn’t have much of a choice between them as they where the same. On this I would have to use flexible plywood to make sure the bend on the edges was stable, also this is the easiest wood to bend as I can steam bend it. I have added a shelf and a draw to put items in so they don’t get lost or clog up the table top. On this I would add a wood protector to make it waterproof. I would nail the pieces of wood together and then use a gloss paint over the whole thing, this will give it a colour scheme and hide where the nails have been put into place. I will place feet on my design to make sure that it doesn’t roll over, this will also prevent the wood from scratching any floor if I add fabric to the bottom. I will cut each peace of wood out using CAD/Cam to make it more accurate, this will improve the standard of my work.

I wouldn’t be able to make this idea as it involves things that I would not have the ability to do. I would make this product out of a mixture of woods, I would do this so that it would have different aspects to it. I would use plywood on the table top so I can add a nice finish at the end, I would also be able to make this waterproof by adding a wood protector to it. I would use MDF for the legs as it is cheaper and easier to work with, this would also make it easier to cut each section out at the side. Each part would be designed and cut out using CAD/CAM saving my time but making it better overall. I will use dove tail joints on the corners to make the table stable and also make it so the table cant be taken apart. I would add PVA glue to make the hold even stronger. To make this I will use recycled woods, this will make my item more environmentally friendly but also the woods will have different shades to them making the colours better. I like this piece because of the sides have a unique style.

Initial Ideas

Initial ideas

I chose to draw this as it have something different than what any other design has. The Bars that will hold the table top up will be make out of light gathering acrylic plastic, I chose this material as it doesn’t cost much and it will give my project a really nice aspect, I will cut each one of these to the same length by designing them on the computer and just copying each design every time. I will try to create a draw in this between the rods, I will do this by lining up each rod and adding runners along them this is were I will attach the drawer. I will make the table top also out of acrylic as it is already waterproof and I will be able to cut it out on the laser cutter, this will make my table more accurate. To glue each acrylic rod together I would use a tensol glue.

To design this I used one of Allesi’s design to create the main shape. I will make the shapes out of wood using the router as this would make my work more accurate. The hole in the centre of the shapes will be used to place magazines in for storage, I will do this by getting a strip of plywood and bending it into a circle, I would then slot this in the holes to create a tube shape. To make the table top I would design a acrylic plastic shape on the computer and cut it out on the laser cutter, I have chosen acrylic as it is waterproof and it wont require a finish on it. Too attach each of the shapes together I will use wooden dowel rods with PVA glue to hold them in place. I will use Araldite glue to attach the table top to the wooden holders.

I created this design so that it would fit into a garden environment and not look out of place. I would make this out of Plywood, this is because if I used MDF the water would turn the wood back into mulch and would be completely ruined. Also I would be able to add a gloss paint to the wood to give it a nice block colour and also to make the wood more water resistant. I would cut most parts using the router but some parts like the leaf I would be able to cut out by hand using a coping saw. I would glue each part together with PVA glue. The steam would attach to the black at the bottom using a mortise and tenon joint, I would use this as it will give the best possible fit and also the most stable. This design does not meet all of my specifacation therefore if I was to make this I would have to make some changes and add other aspects to it.

This was the first design I came up with. I designed this by looking online and looking at what most coffee table included. From here I looked at my specification and what I needed to include. Here I added different aspects that I thought would give my item more of a chance of being successful. In this I would have half the table top to open to store items in as well as having the drawer to put other items in. I would make this out of MDF as it is the cheapest wood I can use and it is the easiest wood to work. On the bottom of each leg I would put a fabric so it doesn’t scratch any floor that it is put onto. To attach the legs to the table top I would mortise and tenon joints with PVA glue inside them. I would use these as they are the easiest to make. To make the draw I would attract two runners the four legs and hang the draw off of that. I would finish this off with paint to make it water and stain proof.

Materials

I will be able to use acrylic plastic to construct most of my table as it is easier to work with than wood. I will also use some plywood on the legs so that it is more stable, also plywood will look god with the acrylic if the right colour is chosen.

Materials

I will be able to use acrylic plastic to construct most of my table as it is easier to work with than wood. I will also use some plywood on the legs so that it is more stable, also plywood will look god with the acrylic if the right colour is chosen.

Finishes

I will not have to add any finishes to the plastic. As it is already impermeable, I will just have to clean it. I have decided to use a clear varnish on my plywood legs as it will bring out the grain in the wood, also this will make the wood water resistant.

Finishes

I will not have to add any finishes to the plastic. As it is already impermeable, I will just have to clean it. I have decided to use a clear varnish on my plywood legs as it will bring out the grain in the wood, also this will make the wood water resistant.

Joints and Components

I will use a cross halving joint to attach my legs together as these are easy to cut out using a hand held jigsaw and will give my wood a nice tight fit so they wont come apart.

Joints and Components

I will use a cross halving joint to attach my legs together as these are easy to cut out using a hand held jigsaw and will give my wood a nice tight fit so they wont come apart.

Ergonomics

I will have to ensure that my design is ergonomically suitable, for example I will have to make sure it is at the right height to be used properly rather than be too tall or to small. I will also make sure that I use a colour scheme rather than just have random colours dotted around my table.

Ergonomics

I will have to ensure that my design is ergonomically suitable, for example I will have to make sure it is at the right height to be used properly rather than be too tall or to small. I will also make sure that I use a colour scheme rather than just have random colours dotted around my table.

Social, moral and cultural

I will need to ensure that my design isn’t offensive or that it seen to encourage violence. I will have to make sure that any designs are not offensive to a particular religion. Finally will have to make sure that my project is modern so modern so that doesn’t impact anyone.

Social, moral and cultural

I will need to ensure that my design isn’t offensive or that it seen to encourage violence. I will have to make sure that any designs are not offensive to a particular religion. Finally will have to make sure that my project is modern so modern so that doesn’t impact anyone.

Adhesives

I will use tensol to glue my acrylic supports to the table top. I will also use PVA glue to glue my wooden legs together. I will have to add some araldite glue in the joint between the wood and acrylic so that they wont come apart.

Adhesives

I will use tensol to glue my acrylic supports to the table top. I will also use PVA glue to glue my wooden legs together. I will have to add some araldite glue in the joint between the wood and acrylic so that they wont come apart.

Design Strategy

DevelopmentThis is my original design that I made based on ‘Agave light’ by Diego Rossi. From here I added legs to it to ensure it is the correct height. I have decided to use a cross halving joint on my product as this is the easiest joint for me to make and also a strong joint if PVA glue is added to it. I will design this on 2D design and use the box router to cut it out, I have chosen this method as it is the fastest and most accurate way for me to cut these out. If my product was mass produced it would be faster and cheaper then getting people to cut them out individually. Plus giving it a more quality, aesthetic appeal.

For the supports for my table top I am also going to use cross halving joints to make them fit in the best possible way. I will have to adapt two of the joints to ensue the four shapes all fit together in the centre. Within the cross halving joint I will add tensol glue to make the hold stronger. I will design these on 2D design and use the laser cutter to cut them out. This will ensure that they will all fit together perfectly with much work needed by me. This would be an advantage if made in batch as few workers would be needed making it faster and cheaper.

The table top will be made using 3mm thick acrylic which can be cut easily on the laser cutter to give it a good quality edge.

I will fit the legs together using a cross halving joint as this is the easiest joint to cut out that will give me a strong fit, I will also add PVA glue to further improve the hold. I will mark out the cutting lines on my wood using my card model and cut the legs out using a hand held jigsaw, then file and sand using wet and dry paper.

Development Added new table top as my originally chosen design was not suitable as it did not give enough room to use, also there was no storage space. This means that my product will better match my design specification. I will make this table top out of acrylic as it is easy to design and cut using CAD/CAM. I don’t actually like the shape as it’s too plain and doesn’t do the base justice. It hides all the key features and is way too big.

Here I have changed the shape of the table top as I liked the idea but I felt being used as coffee table the corners on the table were too dangerous if you were to walk into it. This shows off the base more and allows all joints to be seen and appreciated as I’d like them to be.

Here I have added and changed different aspects of my original design. I have made these changes so that my product will meet my specification and also so it is more suitable for a household.

Here is the original design for my table. I will have develop this as it does not meet all the requirements in my design specification. I will need to add a new table top and somewhere to store items.This will be made out of a mixture of plywood and acrylic plastic, I am using acrylic as I can design this and cut these shapes out using CAD/CAM.

Modelling and Testing

I made all of my card model using CAD/CAM. I used the 2D Design programme and the laser cutter to cut all of my card out and then stuck it together with tape. I decided to make my card model using completely CAD/CAM as I knew this would make my card model completely accurate.

After finishing my card model I have decided I will have to make it 20mm taller in size so It can be used as a coffee table. Other than this I feel that the size of other parts of the table are all what they should be.

I feel my product has been mostly successful as it works as it should do but there are a few thing I need to add to my product to ensure it meets my initial specification. Below the table top where the supports hold the table top I will have to add something to use as extra storage space.

In making this card model it has shown me ways that it can be improved but it has also shown me the advantages of my design as it is easy to move around and looks good in its correct environment. Additionally it could do with being slightly bigger than this.

The table top has a radius of 250mm, this is the same width as the bottom of the table legs. Overall the table is 320mm tall.

Final IdeaThis is the main table top that will be used, I have made two indents in the circular table to place cups/mugs in. The table top will be made out of Acrylic as this will be easy to design and cut out using CAD/CAM, also using plastic is my product was made in batch production this would be fast and cheap to build and at the end of its use can be fully recycled.

I decided to go with the conventional four legged table as I feel this would make my table the most stable preventing it from falling over. The legs will be made from 12mm Plywood that I will cut using a hand held jigsaw. I chose to use plywood as it had a good final finish when varnish is added to it also it if recyclable making my product better for the environment. I will add a clear varnish to my plywood to bring out its grain making it more aesthetically pleasing. As this is wood this is also fully recyclable ensuring my table is good for the environment.

To attach the legs together they will be two long strips of plywood with the shape needed on the end, in the centre of both pieces I will use cross halving joints to securely add the legs together. I will also hand cut these using a jigsaw.

Plywood isn’t a hard material to work with so if my product was made in batch production it would not take long to cut out and put together.

I decided to use a flat base for my table as I felt that this would make it most stable. On a table the items placed on can be heavy so a flat base ill prevent any legs from snapping or the table falling apart.

I will make the table top supports out of acrylic plastic, I have chosen acrylic as it has a good look with plywood if the right colour is chosen, Also it is more environmentally friendly then glass. They will be designed and cut out using CAD/CAM. This will speed up the time of making my product giving me more time to focus on the harder, more time consuming sections.

Part Material Thickness Size Colour Quantity Finish to be applied

Table top Acrylic 3mm 200mm-500mm

Frosted blue

1 N/A

Legs Plywood 12mm 200mm-500mm

N/A 2 Clear Varnish

Table supports

Acrylic 3mm 500mm Diameter

Frosted blue

4 N/A

Cutting list

3mm

40

0m

m

200mm

Step by Step plan

Start

Gather 12mm plywood for table legs

5 min

Draw around template and mark waste lines, 10min

QCAre

markings correct

Mark out joints on wood,

10minCut out shape

using hand held jigsaw, 30min

Clamp plywood to desk with G-clamp, 1min

File and sand wood to make

same size, smooth all edges, 2hr

Design shape on 2D design for table top,

1hr

Gather 3mm thick acrylic

and place on laser cutter,

5min

Design shape on 2D design for table top

supports, 30min

Gather 3mm thick acrylic

and place on laser cutter,

5min

Attach the supports to the

table top, 30min

Attach legs to the rest of the table, 30min

QCAre

markings correct

QCIs the shape

correctly cut

QCAre both shapes

the same

QCIs the shape

correctly cut

QCAre the piece’s

correctly attached

QCAre the

legs correctly attached

QCIs the shape

correctly cut

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Finish

Buy clear varnish finish.

10min

Apply finish to plywood,

30min

QCIs the paint good

enough.

Yes

No

Evidence of CAD/CAM

Over the years CAD/CAM has been used more in the manufacture of products. This helps speed up batch production lowering the cost to make a product. Also less workforce is needed as machines do most of the work increasing the money made by a company. Some disadvantages of CAD/CAM are that it is less environmentally friendly as the machines are run using electricity which is burning more fossil fuels and creating atmospheric pollution.

On my product I have used CAD/CAM to design and make my table top and supports. To design my product I will use 2D design to design the shapes and then will cut them out on the laser cutter. This will make my cutting out more accurate and it will be faster rather than me cutting it out by hand.

If my product was made in batch production CAD/CAM would be used in a similar way but on a larger scale. It would be designed on a computer before hand and then be used to cut out the shapes on a machine.

These are some of my designs that I designed on 2D design so that they could be cut out on the laser cutter. I used 2D design as it is easy to make my designs and get them cut out on the laser cutter.

Here is the laser cutter cutting out some of my shapes. I used the laser cutter as this made making my acrylic shapes faster and also more accurate.

Settings:Speed- 1.7%, Power 100%

Manufacturing Diary

Here I am cutting the legs of my table. I used the jigsaw so that I could get the best possible cut in the fastest time. I clamped the plywood to the desk with a G-Clamp so the wood would not move.

Here is my wood after it was cut. Here I checked it against my card model to ensure it was the correct size. I made a card model first so that I could ensure all parts of my table were the correct size.

Here I am sanding my wood, I used three different pieces of sand paper to give me the best possible finish. I did this as it was cut a millimetre to large and also so I could get a smooth edge.

Here I have attached the upper part of my card model to my plywood legs. I did this to see how I could find a way to attach the two pieces together.

Here are my table legs ready to be varnished. I had to set up in a ventilated area and wear a mask to help stop breathing in the fumes off of the varnish.

Here I am varnishing my plywood. I decided to use varnish as this would bring out the grain on my plywood to give a good finish. I tried to get the varnish with the least amount of VOC’s so that it would be better for the environment and my lungs!

Here I am using wire wool after each coat of varnish. I am doing this so that in the end the finish will be better, after each coat the wire wool removed any access that became stuck to the wood from in the air. This made sure it had a nice smooth finish which had no lumps and bumps on the surface.

Whilst making my project I took pictures of each major process; I did this so I could show how I constructed each part of my project.

Here I am using 2D design to design the acrylic parts for my table. I used 2D design as this means I can now use the laser cutter to cut out my acrylic shapes, this will make my work more accurate and be completed in a faster time. This also helps my product as if it was made on a factory line it would speed up the process and save money. I made sure all settings were correct and they were nested together to save materials and money.

Here are my acrylic shapes being cut out on the laser cutter. I am using CAD/CAM on my project as this mean I could easily cut out and assemble my projects.

Here I have cut out my plastic shapes on the laser cutter. I used the laser cutter so I could get the best possible cut.

Here the laser cuter incorrectly cut out my acrylic circles out wrong. I had to redesign my shape so that it would be cut out right.

Here are the joints for my table top supports. I cut all these part out on the laser cutter so they would fit perfectly together. I used liquid solvent cement to glue these together, this gave me the strongest hold leaving the least amount of marks. I made sure I applied this with a fine paintbrush to avoid any stains on the surface.

Testing aesthetics of table construction

Here are six different designs of what combination of wood and acrylic I could use for the section between my table legs and table top supports. I have spaced out the different pieces of acrylic in different patterns to see what other think / feel about the design before finally gluing it together. I gathered the view of others before making a final decision:

Miss QuinnI prefer idea 3 because I like the way each light gathering blue piece of acrylic is separated evenly helping the light to shine through them all more evenly. This also makes it look more symmetrical and I prefer this controlled aesthetic appeal. Definitely choose this option!Karen KeatingIdea 5 is good because of the staggered finish. I like the way the LG blue pieces go in and back out again in a staggered style. I think the light shines through this better and you can see the blue colour more than the others.Daniel BrownbillI prefer number 5. I like this idea as it will make the table more unique as these circles are used in a unique way.

After careful consideration, I decided I agreed with Miss Quinn, although it was difficult to decide between this and idea 5 because they both allow equal amounts of light through the design. I glued all acrylic pieces together with tensol for a strong, long lasting finish.

1 2 3

4 5 6

Evaluation against Specification

After looking at my original specification, I feel that the table meets Most Points given. This is because I worked hard to make sure that all aspects were made correctly and safely to avoid mistakes and waste of materials, this was done by having quality control checks at each stage of the making process and constantly looking at my folder work to remind me what I set out to do..

My design must: Reason:

Have a target audience from the age of 20-45. To give my item a large area to sell in. I chose this age range as these are the main people that are buying new homes and looking to furnish them.

Have a place to store items To store items in so that the table doesn’t get filled with junk. This will also add an extra aspect to my project. To do this I will add a draw or a shelf to place items on.

Not include any offensive language or images.

So that my item isn’t offensive to any religions or anyone else. Also I may not be able to make my project. To make sure this doesn’t happen I will research into things that may be found offensive and not include them in project.

Be a suitable size So that it will fit into a house and be at the correct size for the proper use. 449.0mm in height, 153.9mm in depth and 153.9mm in diameter, I found that this would be a suitable size for my coffee table to be.

Have a consistent house style So that my item will have a good chance of selling and it wont look out of place. Also if it doesn’t have a consistent colour it won't look right.

Be suitable to its environment So that it wont look out of place and will fit properly indoors. Also if I put my item outdoors it will have to be waterproofed. Additionally even if it is kept indoors my table top will have to be waterproof so that if anything is spilled it wont be absorbed.

Have a low cost So that I will be able to afford to make so that I am not restricted when making my product. Also if I am to sell my item the cost to make will be have to be as low as possible so that I can make more profit of it when selling.

Be waterproof So that if anything is spilled it would be absorbed. Also if it is moved outdoors and it rains the product wont be completely ruined. I could do this by using plastic or if I use wood add a waterproof finish.

Have holes to place glasses/mugs in So that they wont slide around on the table. This will also help to prevent spillages on the table. I will cut these out using the laser cutter.

Use suitable Materials For my table top I will use acrylic as it is already impermeable and for my legs I will use Plywood or MDF as it is more stable than plastic and also cheaper when using to make.

Have a finish I wont have to finish my acrylic apart from cleaning it, I will use varnish on my wood legs so that is becomes more waterproof and the aesthetics is improved.

EvaluationThe task I was set was to design a modern styled coffee table aimed at the first time buyer for a high street retailer. I chose this task as I already had Ideas that I could use that were original and modern.

I feel I met this specification for my coffee table well. I ensured that the specification was met by referring back to it when creating my ideas and when developing my idea, this made sure all points in my specification were met.

I feel that my product is easy to use as I have designed it so it will do all of its intended purposes. When designing and creating my product I always thought of the consumer making sure each part was easy to use, I tested various different ways to create my product so that I could get the best possible design with the easiest useable functions. One difficulty may be that my table top is not glued on, this could make the table hard to use as this can slide around and be knocked off. If made in industry this would be made out of glass and there would be rubber stoppers to hold it in place. The acrylic is too thin to add rubber stoppers at this stage so I cannot include them.

I have tested the table with various items that would be used on a table and I feel that the table works the way it should. This is because the techniques I used were difficult but they made it easy to create a table that is easy for the consumer to use.

Consumers OpinionsI have asked some people that are within my target audience and the majority of people thought that my product was a good modern style with a smart colour scheme.

‘The way all components of the table fit together work well as this could have easily made the table become unappealing, I would pay £20-£30’

‘The tables colour scheme makes it easy to fit in most parts of my house, I would pay around £25’

‘To get the best possible use out of the table I feel it will need to increase in size, £40 would be to top possible price.’

‘An advantage of this product are that it will be hard to find anything else like it on the market, this makes it a unique table.’

‘The only disadvantage of this table is its size. it needs to be much bigger to make an impact and so it us useable in a modern day household’.

When creating my product I tried to be as environmentally friendly as I possibly could. I used materials that could all be recycled. The plywood I used had already been recycled from another product and taken from the eco bins in school and I tried to use varnish with the lowest VOC’s to have less impact on the environment.

ModificationsIf I was to make my product again I would ensure that I had larger equipment so that I could make it bigger overall, I feel that the size of my coffee table was held back due to the lack of facilities available to me. If I had a larger laser cutter and Boxford router in my school to use for my CAD/CAM my table may have been a more suitable size.

In this image you can see a small gap in my product. If I was to make my product again I would ensure that nothing like this was present. To fix any problems like this I would have to re-cut out the acrylic on the laser cutter, I was not able to do this as I did have much time left to complete my product and it would waste too much acrylic. Therefore if this was made again, I would make sure the design was 2mm higher on the shorter side to make sure the table top rested perfectly.

Here is a small splinter on my plywood. If I was to make my product again I would ensure not splinters were present on my table. To make sure of this would use machines to cut out my plywood so that the wood didn’t need sanding preventing any splinters from occurring. I could use the Boxford router to create a high quality finish.

Throughout the process of my designing and creating I had to make numerous changes to ensure that my table worked well, these changes ranged from changing the colour scheme to changing an entire section of my design. These changes made me really think about my product and how it would work. If I was to make another product I would have to do a lot more planning before I started making to prevent drastic changes being made in the middle of creating the product.

If I was to remake my product I would try and find other ways of making it so that I could be more environmentally friendly. I would try to use a different finish that had less harmful chemicals in it. I would try and use more recycled materials so that nothing useful was wasted.

Final ImagesHere are the images of my final table.

I took photos of my table from as many angles as I could. I am happy with my final product as I think it met all of my aims I set and it met my design brief and specification apart from I decided not to have holes for the mugs as this would limit where people could place their mugs and also get germs in causing bacteria and dirt. I have evaluated my product in the previous slide and shown what improvement have to be made if I was to make it again.

When designing my product I took into account designs that I could use for inspiration and the opinions of the consumer, this has helped me to achieve the best possible product I could that successfully meets all of the criteria apart from one explained above.

Here is my table in use

The Life Cycle of a Coffee Table - (Plywood)

•The plywood for my table starts out its life as a simple tree.•This will then be cut down and collected.

•In the factory the wood is cut down into sheets.•From here to plywood is sent off for the wood to be used.

•The plywood is sent to my school workshop•The wood I used was an off cut of the original sheet of plywood.

•The plywood has been used to make the table legs.•This should last for a few years before it breaks.

•The plywood from my table can be recycled at the end of its useful lifecycle.

• The recycled wood is sent to another factory and cut down into wood chippings.•Here it is turned into MDF. Then it goes back to suppliers and schools for more manufacture.

The Life Cycle of a Coffee Table - (Acrylic)

•The oil is extracted from the ground using an oil rig.

•In the factory the oil is broken down and separated.•Here it is made into the acrylic plastic

•The acrylic is sent to my school workshop•One of the sheets of acrylic I used was an off cut so I was being more environmentally friendly.

•The acrylic plastic was used to make the upper part of the table.•This should last for a few years before it breaks.

•The acrylic from my table can be recycled at the end of its useful lifecycle.

• The recycled acrylic is sent to another factory and melted .•Here it is used to make other plastics e.g. plastic bottles.