Fold Flat Furniture

Christian DeLavalette Oliver Filley Janae’ Javis
Hyn Lee So Whi Lim Nitika Shah
Professor Chen
IDUS 100-01: Spring 2013
Pack Flat Furniture

Contents
Problem
Target Market
Market Research
Ideation
Scale Models
Full Size Models
Pack Flat Furniture Christian DeLavalette • Oliver Filley • Janae’ Javis • Hyn Lee • So Whi Lim • Nitika Shah IDUS 100 SCAD Spring 2013 1

Problem
Houses without furniture are difficult to sell because potential buyers cannot en-
vision what to do with the space. To remedy this problem, individuals have be-
gun using furniture to stage the living space. This technique is generally referred
to as a stage furniture or staging homes. According to the US Housing and Ur-
ban Development Department (HUD), staged homes even sell for more than
their empty counterparts, averaging 17% above the listing price.
About Stage Furniture
The Conundrum
Section Contents

About Stage Furniture
Stage furniture can also be rented from various companies. This furniture can be real or made of cardboard, but is only helpful for individ-
uals who are selling houses on their own. Real estate agents would only benefit from a rental situation if they only have one house without furni-
ture that they must sell. However, real estate agents often have to sell multiple houses at a time. Many of these houses lack furniture. As a result,
it would be useful for them to have lightweight, easy to transport furniture that can be set-up and used in multiple houses.
Julia De Sosa-Rocha, a real estate agent in Atlanta, Georgia, better explains the advantages of cardboard furniture in this excerpt from her
blog: “My real estate experience shows that staged homes sell faster and for the higher price than the empty houses. But here is the question:
“What if the seller doesn’t have a lot of cash to have the home staged?” Cardboard / “Fake” Furniture can be a good low-cost solution to stage va-
cant homes for sale, model homes, showrooms. I’ve shown a lot of empty vacant homes to my buyer clients in the last several years and I noticed
that some of them cannot or have difficulty to visualize how the house will look like with real furniture. I think we have a solution now. I don’t
think that furnishing a million plus home with a cardboard furniture is a good idea but it can be definitely an alternative solution to $100,000 -
$300,000 homes.”

The Conundrum
Although cardboard furniture is very advantageous due to its lightweight and compactability, it provides it’s own array of problems. The main
problem is that a majority of cardboard furniture is dull and boxy. It is also obviously composed of cardboard. While some companies have
sought to alter this by adding cushions and fabric, in terms of design, the furniture does not do much more aside from filling space. As a result,
there is a market need to produce stage furniture that can fulfill all of the advantages of cardboard, but also provides some aesthetic consider-
ations for a more realistic representation of the space.

Target Market
The target market was selected after lengthy group discussions and research. The
location was selected first, followed by the demographics then style of furniture.
Initially, cities such as New York City and Dubai were considered; however, the
location changed due to feasability concerns.
Location
Demographics Research
Living Room Dimensions
Style
Section Contents

Location
Although the weight and portability of the furniture is aimed at real estate agents, the style is based on home buyers in Clear Lake City, Texas.
Clear Lake City is a segment of Houston, Texas, that is close to companies such as NASA, Boeing, Lockheed Martin, and multiple chemical com-
panies. The individuals most likely relocating to Clear Lake City are aerospace engineers, mechanical engineers, chemical engineers, manufac-
turing engineers, and electrical engineers. The community itself is predominantly Asian-American, composed of individuals of Chinese, Viet-
namese, Indian, and Pakistani descent.
To provide some insight into the individuals moving to Clear Lake City, employment patterns and median pay were researched. The city of
Houston employs 33% of Texas’s aerospace engineers. The median pay of aerospace engineers in the area is $113,880. This means that they can
afford to purchase the large spacious homes in Clear Lake City.

Demographics Research
In order to get a better understanding of the demographics, more research was conducted concerning engineers. The engineering workforce is
89% male. From the National Society of Professional Engineers 2004 Report on the Engineering Profession, 61% were between the ages of 30-
49 and 19% were foreign born. Among all engineers, 80% were white, 12% were Asian, 6% were underrepresented minorities such as Hispanic
and Black, and 2% were temporary residents. This means that although Clear Lake City may be mostly Asian-American, the odds are higher that
incoming engineers are going to be white males.
To completely define the demographic, divorce rates and living arrangements were analyzed. In the US, 41% of first marriages end in di-
vorce, with the age of the first marriage for men being 27 and the age of the first divorce 30. Around 75% of the time, children live with their
mother after a divorce. A majority of divorced individuals get remarried with 60% of remarried couples being between the ages of 30 and 49.
However, it must be taken into consideration that 60% of all second marriages end in divorce. This means that statistically speaking 36% of those
remarried between ages 30 and 49 will get divorced a second time.
Engineers by age:

Demographics Research (continued)
Overall, the statistics on divorce neglect how many individuals are married at a given time and how many people actually live alone. For individ-
uals between the ages of 30-49, in the 2010 census, 21% never married, 66% married, 10.95% divorced. In 2010, 10% of individuals between the
ages of 25 and 54 lived alone, 58% with a spouse, and 31% with others. In the state of Texas, in 2009, the divorce rate was 10%. This made Tex-
as one of many states with a higher divorce rate for men than the national average of 9.2%. However, these statistics differ for Asian Americans.
According to the 2008 Census, the divorce rate among Asian Americans was only 5%. In 2010, among individuals between the ages of 25 and 54,
7% lived alone, 68% lived with spouses, and 24% lived with others. In order to accommodate the demographic, it is necessary to create furniture
that accommodates single men as well as those with families or roommates. This is because it is less likely that individuals over the age of 30 live
alone.
Considering all of the research, the furniture will be targeting engineers between the ages of 30 and 49 who are relocating to the area. These
engineers will most likely be living with other people whether they are spouses, children, siblings, or roommates.

Living Room Dimensions
The dimensions of a lving room vary from house to house. Some are rather small whereas others are extremely spacious. Stereotypically, things
in Texas are bigger compared to other areas in the United States; however, to properly assess sizes, a more mathematical approach was utilized.
Ten different houses on the market in Clear Lake city were used to calculate an average living room size. In order to improve the viability of this
method, more houses (on the order of 100s) would need to be assessed in order to yield a more accurate living room size. However, for the pur-
pose of this design, a more approximate value is acceptable. After the analysis was completed, it was found that an average living room in Clear
Lake City, Texas is approximately 22.5’x27’ (180”x216”).

Style
In many homes, the living room is one of the first areas seen within a house. It is often the largest open space and one of the major selling points
for a house.The style selected for the furniture was contemporary furniture with a modern twist. This particular style encompasses a majority of
furniture currently in Clear Lake City homes that are on the market. The modern, transitional style allows for the creation of more creative, less
boxy shapes.

Market Research
Market research was completed to better understand what types of furniture in-
dividuals were using as stage furniture as well as what type of furniture could be
easily folded or stored. Most of the evaluated furniture is created with cardboard
, and is chosen because cardboard is the current material on the market that is
being used to create stage furniture.
Competitive Products
Section Contents

Competitive Products
Chairigami chair
Cost: $80
Features: Can transform into a stacking shelf
Where to buy: Chairigami.com
Pros: versatile, sustainable
Cons: confusing to assemble
Chairigami sofa
Cost: $120
Features: Can be folded into a flat shape
Pros: a fraction of the cost of a real sofa
Cons: lacks armrests
Chairigami coffee table
Cost: $85
Features: Can be folded down into a flat shape
Pros: sturdy, folds easily, can withstand water damage
Cons: dull overall shape
Chairigami arm chair
Cost: $180
Features: arm rests
Pros: ergonomic, distributes weight
Cons: bulky
Next Stage dining set
Cost: $379
Features: standard chairs and table
Where to buy: Nextstage.com
Pros: easy to assemble
Cons: weighs 42 lbs, not as easy to move

Competitive Products (continued)
Next Stage living room set
Cost: $459
Features: couch, chair, coffee table
Pros: resembles real furniture
Cons: boring shapes
Karton Dutch Design Chair
Cost: $49
Features: a chair that can also be a table
Where to buy: kartongroup.com.au
Pros: versatile, different style options
Cons: very simple shape, chair lacks a back
Next Stage classic living room set
Cost: $759
Features: couch, chair, ottoman
Pros: easy to assemble
Cons: lacks a coffee table, very heavy (89 lbs)
Karton Chairman’s table
Cost: $148
Features: extra strength cardboard
Where to buy: kartongroup.com.au
Pros: quick assembly
Cons: only raw material
SK109 Cutting Table
Cost: $399
Features: collapsible drawers, storing box/bag
Pros: easy to transport
Cons: pricey

Ideation
Each team member completed 15 sketches total with 5 chairs, 5 tables, and 5
couches for a total of 90 sketches: 30 chairs, 30 tables, and 30 couches. A few ad-
ditional sketches were created in order to improve and finalize concepts. Of the
90 sketches, 2 chairs, 2 tables, and 2 couches were chosen for further exploration.
They were then separated into two separate furniture sets.
Sketches
Finalized Conepts
Section Contents

Sketches: Christian DeLavalette

Sketches: Oliver Filley

Janae’ Javis

Sketches: Hyn Lee

Sketches: So Whi Lim

Sketches: Nitika Shah

Finalized Concepts: Couch
The two selected couches were chosen for different reasons. The first couch was pinpointed due to visual appeal and it’s capability to fit different
styles of furniture. The second couch was chosen because of it’s versatility and ability to fill the spacious living rooms of Texan houses.

Finalized Concepts: Table
The first table was chosen because it curves in a manner that matches the second couch. It was also designed to be easily folded. The second ta-
ble was selected due to its simple design and curved form.

Finalized Concepts: Chair
The first chair was picked due to its storage capabilities. The second chair was indicated since its design matched the curves present in the second
couch.

Finalized Concepts: Furniture Sets
Set 1:
Set 2:

Scale Models
The two sets of living room chosen at the end of the ideation section were then
built at a 1/8 scale of the final model size. This was done in order to determine
which furniture set was best. The models were built using hardboard, epoxy,
cardboard, tape, foam, and fabric. The sketches were first scaled and dimen-
sioned before 2D drawings were created in Rhino. These drawings were then
used as profiles for laser cutting. The laser cut hardboard was then modified
with Dremels and other cutting tools before they were assembled. Pieces of foam
were cut using the wire cutter and sanded to create accent chairs, a table, and
stuffing for cushions. Fabric was then wrapped around the stand-in cushions
and taped into place. After their creation, the pillows were arranged on the fur-
niture in an aesthetically pleasing manner. Of the two furniture sets, one set was
selected to be created at full size. The selection was made based on the aesthetics
and functionality of the furniture.
Profile Samples
Process
Final Scale Models
Selected Furniture Set
Section Contents

Profile Samples
Using Rhino, 2D profiles were created to be laser cut. Below are samples of a few of the modeled curves.

Scale Model Process
Team members determining couch size. Cut profiles from the laser printer. Laser cut profiles for the couch. Oliver dremeling notches.
Partially assembled couch. Half of the couch after adding armrest. Side view of the armrest. Front view of the right half of the couch.

Scale Model Process
Fully assembled couch. Foam block used to create cushions. A shot of the first couch with cushions.
Couches covered with fabric. A view of the chair from the second set. Sample living room arrangement. Another living room arrangement.

Final Scale Models: Set 1 Couch

Final Scale Models: Set 1 Chair

Final Scale Models: Set 1 Table

Final Scale Models: Set 2 Couch

Final Scale Models: Set 2 Chair

Final Scale Models: Set 2 Table

Selected Furniture Set
A majority of the second furniture set was selected to be created full scale; however, many elements from the first set were pinpointed as ideas
to pursue. The couch from set 2 was selected due to the shape of the backrest and the versatility of the chaise. The chair concept from set 1 was
selected due to its storage capabilities and portability. The table from set 2 was chosen, but in order to enhance the aesthetics, the final model will
feature the cut out and recessed surface of the table from set 1.

Full Size Models
After selecting the final furniture set, full size models were created. The full scale
models were created in a similar manner to the 1/8 scale models. Dimensions
were reassessed for the couch and coffee table. The files were then adjusted for
laser cutting. After some searching, quarter-inch birch wood was selected for
the final material. The material was then laser cut and assessed. It was discov-
ered that the proportions for the back of the couch were off despite the usage of
official dimensions. To remedy this problem, modifications were done by eye
using a ruler and adjusting the height of the couch. More material was pur-
chased and while the couch was being re-laser cut, the coffee table was assembled
and stained with cherry stain. The remainder of the wood was stained, then the
couch was assembled. During this process, the chair and additional table were
created using cardboard. However, it was found that the chairs were to complex,
resulting in the design of new chair. It was also discovered that the chaise con-
cept was to boxy, and subsequently omitted from the final model.
Final Sketches
Rhino Renderings
Design Modifications
Process
Final Models
Section Contents

Final Sketches: Couch

Final Sketches: Chaise

Final Sketches: Table

Final Sketches: Chair

Rhino Renderings: Couch Front and Back View

Rhino Renderings: Final Couch

Rhino Renderings: Chaise

Rhino Renderings: Table

Rhino Renderings: Chair

Rhino Renderings: Final

Design Modifications: Chaise
During the building process, it was found that the original box structure for the chaise would not function as desired at full size. To troubleshoot
the problem, various sketches and small models were constructed. Despite the adjustments, the overall shape was too boxy, an undesired feature;
therefore, the chaise was excluded from the final design.

Design Modifications: Chair
It was also discovered that the original chair concept was too time consuming and complex to pursue. The images below display the work that
was completed on the chair.

Design Modifications: Chair
In order to remedy the problem, a new chair was designed. For proof of concept, a small scale model was constructed using cardboard. After
testing the idea, the chair was greenlit and created full scale.

Final Model Process
Final laser cut pieces. Oliver dremeling exposed screw threads. Sketch of hinge placement for the table. Grid system used for the discarded chair.
Minwas cherry colored wood stain. Wood stain applied with a brush. Stain applied with a cloth. Side by side comparison of applications.

Final Model Process
Piece of the table drying after staining. More pieces drying. Nitika and friends measuring fabric. Nearly completed couch cushion.
Stained table ready for assembly. Couch pieces laying on table. Additional couch cushions. Laser cut chair pieces to be assembled.

Final Model Process
Fully assembled couch. Christian assessing the couch stability. Chair being used to lift middle of couch.
Transporting furniture in a truck bed. Oliver and Christian inserting folded leg. Christian dremeling screw threads. Nitika assisting in powering the dremel.

Final Model Process
Shot of the chair folding mechanism. Underpiece for the table. Jamie inserting Bristol for the chair. Detail view of the Bristol being folded.
Shot of the chair assembly. Back view of the chair. Chair after adding Bristol to the top. The chair fully constructed.

Final Model Process
Paint job completed on table and chair. Nitika sewing a cover for the chair. Detail view of the sewing process. Another sewing detail shot.
Nitika and Oliver assembling the couch. Nitika and Oliver folding the couch. Oliver pushing Christian for the video. Another shot of the panned views.

Final Models: Couch

Final Models: Table

Final Models: Chair

The Team
Christian DeLavalette
So Whi Lim
Oliver Filley Janae’ Javis
Nitika Shah
Hyn Lee

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