Corrugated Board Chair Project

Below is a video explaining my process throughout the start of my project.

Constraints:

build a chair that can hold a human adult (target = 180 pounds)
we can use only 2 sheets of corrugated board (48 x 96in)
it must be aesthetically pleasing
it must be comfortable
it must be portable

Inspiration (from google search):

Sketches:

Design #1:

I loved the look of the vertical placement of corrugated board in my first inspiration photo, so I created a design highlighting the visual appeal. However, after thinking deeper, I have realized that this chair may not very comfortable.

Design #2

Next, I attempted to create a design that is more comfortable, more stable, but still resembles the first design- an upgrated version. As a result, I was also able to make the design more simple and only require two types of pieces.

Design #3

After making two similar designs, I wanted to create something completely different. To do this, I decided on a visually simpler chair. However, the design was not simple at all. While designing, I quickly realized that in order for a chair to appear simple, there would have to be many hidden supports. The individual types of pieces needed would also vary greatly. This design would need the most variety of pieces as well as use more glue than the first two designs.

Design #4

Finally, after creating a model for design #2, I created a design that kept the parts of design #2 that I liked, while adding more support and making it more comfortable. I did this by adding more horizontal supports and utilizing more slanted angles. I also reduced the number of gaps in the design. The result was a chair with a larger variety in parts but builds with the same slot-type junction.

Mini Model #1

After evaluating my first three sketches, I decided on building a model of design #2. The only issue I ran into was that it was not as stable as I imagined it would be. To fix this, I added supports between each vertical piece.

Isometric view

Side view

Back view

Bottom view

Mini Model #2

Creating my second mini model was a very smooth process. Because there is a bigger variety in the dimensions of each part, I was extra careful in my measurements to ensure that everything was proportional. This became my final model.

Isometric view

Side view

Back view

Bottom view

Final Model:

After evaluating my two mini models, I determined that my second model was much more practical as a chair. I built this model to scale in Autodesk Inventor as well as created a flat pattern for it. As a result, I was able to make all of the parts with only one of the two corrugated board sheets. I also created an exploded view of the chair, showing how the parts are arranged as well as revealing the hidden supports.

*I mixed up IPT and IDW in this video*

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