Problem statement
To create a small occasional chair that will support at least 150 lbs. of weight, constructed using only double-faced cardboard and adhesive (no tape or fasteners). Ideally, the chair should also conform to the following parameters:
1. Use no more cardboard than the necessary structural pieces
2. Be less than 24" wide to fit between the foot of my bed and the wall
3. Have a small footprint or open bottom to take up little floor space
Ideation sketches
I started the process by sketching over a hundred different chairs just to get ideas flowing. Here is a small sampling (I've circled the sketches that ultimately led to my final solution).
The final dimension drawing before constructing the chair
Construction
After finalizing the dimensions, I created a cardboard template to cut all the side pieces to the same size. All the parts had to be cut perfectly to the right dimensions in order to facilitate the tight puzzle-piece construction of the seat and backrest. The sides were 3-ply laminated to create sturdy side walls.
Cutting out the templates
Laminating the side pieces with Super 77, the only instance of adhesive used to construct the chair
The final chair, pieced together and ready for testing
Presentation & testing
I presented my final solution to the class and explained my design process, including ideation sketches, paper mockup iterations, and final construction. At the end of the presentation, the chair was tested to see if it could hold the 150 lb. minimum weight limit.
Explaining my 3-D test mockups, exploring form and function early in the process
The moment of truth (thanks to Shawn, our 150 lb. test subject)
The chair survived unscathed!
Conclusion
The completed cardboard chair meets all the requirements of my original problem statement. It holds well over 150 lbs. of weight. It has space underneath for books or shoes, and the seat is the perfect height for tying your laces. The backrest is just high enough to support your elbow, while being low enough not to interfere with your posture. Plus, its 18" width will fit between my bed and the wall with room to spare.
All in all, the chair is successful!
Ryan Johnsen // Design 3600 // Fall 2014
