Flatpack Architectural Step-stool

Hi! We're Paulina and Virginia, and we're excited to introduce you to our step-stool.

The goal of this project was to work together in a pair to build a flat pack step-stool using only a 2 ft by 4ft piece of plywood. Through research, many design iterations and models, material testing, and CAD modeling, we were able to CNC pieces of our stool and put them together into a beautiful, architectural step-stool. For this piece of furniture, we took inspiration from Prairie and craftsman style architecture, specifically that of Frank Lloyd Wright. We especially wanted to incorporate the use of cantilevers as a way to accentuate our design and break out of the bounds normal step-stool. This stool can be easy assembled and disassembled in only a few moments with 11 pieces.

1. 2' x 4' sheet of 3/4" plywood
2. CNC machine
3. Sandpaper
4. Wood Finish
5. Cardstock and Chipboard for Modeling
6. Fusion 360 Software
7. 3D Printer
8. PLA Filament

For our first step, we researched both style and function.

In our research of style, we looked at many different brands of step-stools and saw that many of them looked the same and were very two-dimensional. We used this to decide on the design and purpose of our step-stool; a high-end, elegant stool.

In terms of function, we researched the average dimensions and sizes of the steps in commercial designs to make sure using the stool would be the best experience possible. In addition to online research, we also did a physical analysis to test which step heights and widths were most comfortable for us to use.

In the ideation stage of our project we each quickly sketched many rough ideas of what our stool could possibly look like. From the initial ideation, we each picked our favorites and fleshed them out into more detailed sketches.

With our favorite designs in mind, we then moved on to physical modeling so that we could get an idea of the scale and proportion of our stool. We began with rough sketch models at 1/4 scale. We then moved on to more detailed models at 1/2 scale. For these models we laser cut the different parts for precision and an accurate depiction of how we could CNC the design within the plywood sheet we were given. Our final model was at full scale and gave us a better idea for what our final design would look like.

Before making our final CAD model, we needed to test joints to see what would be secure enough to hold a person, but easy enough for anybody to put together and take apart. To do this, we first tested our joints through layers of cardboard that we laser-cut. Once we has the dimensions finalized, we then used the CNC machine to cut test pieces from plywood to make sure that they were secure.

After looking at joints, we then wanted to test the finishes that we would use on the pieces of our step-stool. We decided that we wanted a 2 toned look to accentuate our three dimensional design, and so we made sure to test different light and dark colors of stain.

We also wanted to etch number into each piece so that it would be easy to tell the order in which it should be assembled, so we tested different etching settings on the laser-cutter as well.

In addition to our CNC parts, we also had one part used in a joint that needed to be 3D printed. In our testing phase we tested different plug types and connections on the 3D printer to enhance user experience.

Once we had a model that we both liked, we moved on to modeling it in the Fusion 360 CAD software so that we could make a file that would be used to CNC the pieces. In Fusion 360, we were able to build each part of the design and then also import the 3D printed joint to make sure that everything fit together perfectly. Once we had a successful CAD model, we then used the assembly feature in Fusion 360 to make all of our parts lie flat on a sheet in the configuration that most optimized our material.

Once we had used Fusion 360 to create our final CAD model and the final assembly of our flat pieces, we turned the file into a DXF file and cleaned it up in Adobe Illustrator so that it would be ready to be sent to the CNC machine to be cut.

After all of our parts were cut, the final step for our step-stool was sanding and finishing. We sanded each piece entirely to 150, 220, and then to 320 grit. Once all of the pieces were smooth and fit together perfectly, we applied two coats of a dark stain to some of the pieces and then two coats of a clear coat to all of the pieces.

Since our step-stool was made to be flat-packable, including an instruction manual essential to our design process. Using the drawing feature in Fusion 360, we were able to have line-drawings of the stool at different steps during the building process. We combined these drawings in Adobe Illustrator and added more detail for the user.

Our very last step was taking high-quality photos of our stool in a studio as well as in a contextual setting so that our project would be documented in the best way possible!