axia
A compact stool crafted for
durable outdoor seating
This project was a group assignment focused on designing and building a functional stool using both wood and metal. The brief required us to incorporate wood joinery techniques and incorperate a metal component while working within strict dimensional limits of 0.5m x 0.5m.
Year
Fall 2024
Timeline
8 weeks
Manufacturing
Woodworking, Joinery, Sanding, Metal fabrication, Finishing
Initial Ideations
When discussing our original idea with the lab techs, it was definitely helpful to have these two things on hand. The techs were able to identify what we were trying to create and recommend changes in materials or fastening methods. The drawings helped both us communicate our intentions to the lab techs and allowed them to explain improvements in assembly and how to execute them.
Manufacturing Phase I
Cutting and Surface Preparation
During the construction phase, we began by processing the smaller planks through a planer to bring them to a uniform thickness of 3/4". The edges were then smoothed using a joiner to remove roughness and prepare the pieces for precise assembly. For the larger components, we measured and cut the planks using a miter saw, leaving a small 1/8" allowance to allow for any necessary adjustments.
We marked the final shapes, flattened the edges with a belt sander, smoothed the faces with an oscillating hand sander, cut the edges to final dimensions with a miter saw, executed the 28.5° angles for the trapezoid pieces using a table saw based on an Illustrator mockup, and finished all pieces by sanding from 160- to 220-grit for a smooth, precise surface ready for assembly.
Then we used a biscuit joiner to connect all flat, non-angled pieces. We carefully created two to three slots in each component.
Manufacturing Phase II
Assembly and Finishing
Once all pieces were sanded, the biscuit joints were inserted and glued to connect the wooden planks togeather and then clamped down.
Guide holes were drilled, and ½-inch screws along with wood glue were used to secure the brackets, which were left to dry overnight. The two halves of the stool were connected in the center with a square piece, reinforced with wood glue, ratchet straps for tension, a central board to prevent collapse, and bricks to evenly distribute pressure during drying.
Thin metal strips were cut to size using a sheet metal shear and glued along the edges to protect the corners during use. Finally, the stool was lightly sanded, stained with a dark finish using a sponge brush, and left to dry overnight. After a second light sanding and dust removal, two layers of Varathane were applied to seal and protect the surface, giving the stool a polished, durable finish.
