fergus hickey
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FERGUS
HICKEY
DT GCSE RESISTANT MATERIALS PROJECT
KING EDWARD VI SCHOOL
CENTRE NUMBER 58625
CANDIDATE NUMBER 2522
A major high street retailer wishes to make a multi-purpose, modern style,
small coffee tale aimed at a first time buyer. The product will require storage
space.
My Table is aimed at young couples, buying a table for their first time. Most
likely, they will not have kids, so it may contain sharper edges or smaller
parts. A modern table will fit in with their potentially new house.
It will probably be situated in the living room, where there is a TV, so the table
will need to provide storage space for TV remotes, games or magazines. It
may also be placed in the bedroom and therefore will need to give room for a
bedside lamp, books and phones. It mustn’t be too large as it may need to be
moved. As there is the possibility of it being a centrepiece, it must be quite
stylish.
It will create my coffee table to comply with the aims of my buyer. It shall be
medium sized, be able to store DVD’s, magazines, and be modern and
stylish. It should also contain drawers or shelves.
DESIGN TASK 11
DESIGN TASK 11
EXISTING PRODUCTS
Mortis and tenon joint, giving the underside
of the table more support.
Finger joint, difficult to make, but will
make this frame much stronger.
On my design, I
will tidy up the
bottom of the
table so when it
is stored or
moved it looks
good
aesthetically.
This could be replaced with
a housing joint.
Silicon pad to protect the
glass from damage.
Plenty of space
to store
common items
like magazines.
Big housing joint, creates a
fine finish.
Possibility to inlay glass
onto this surface.
PRIMARY RESEARCH
QUESTIONNAIRE
Material
Wood
Metal
Plastic
Other
Storage
Draws
Shelves
Glass?
Glass
NoGlass
What is to be stored
DVD's
Magazines
Electronics
Shape
Round
Square
Rectangular
Mix
Finish
Stain
Wax
Varnish
As three quarters
of people said they
preferred wood,
this will be the
material for my
coffee table.
I will try to
implement both
draws and shelves
to cover both
groups
I will place glass
onto my table,
resting on a lip, to
make sure it is
supported.
With both shelves
and draws all of
these items will be
accounted for and
stored easily.
I will make a
rectangular table
with rounded
edges for a good
look.
I will use a wax
finish as this was
popular, it will give
a great finish.
I went around my village asking people if they were a first time buyer, the type
of coffee table they would prefer, these are the results. The typical table that
will please the most people aesthetically is shown by these answers. A Wood
table with draws and shelves, with glass on the top, that has space to store
electronics, shaped with a mix of round and square shapes, with a wax finish
will be perfect for the target audience.
MOOD BOARD
Many first time buyers will have
magazines, DVD’s or books as my
survey shows, and will want a shelf
or draw to store these. They will also
own electronic appliances such as
laptops or iPads to check emails, so
a draw must be big enough to
support these. The buyer will most
likely own a small car and have
keys, which could be stored in a
small draw, above a shelf. Eating
and drinking will also take place on
a coffee table, therefore, I must
make the table with a protective
layer. A small draw or shelf would
also be useful for things like
headphones to a TV remote. A big
space could be used for storing a
stack of DVD’s or plates.
Function
• My design is aimed at first time coffee table buyers, or for couples moving into a new house. The age range is 25-35.
• It will function as a regular coffee table, and should provide sufficient space for plates and cups to stand on top of.
• It will have space to comfortably store magazines, remotes or games.
Aesthetics
• My table will be in the modernistic design style.
• I would like to make the table all one shade of wood, with dark or light.
• As my questionnaire shows, a mix of curved and straight lines is the most popular design for the outside of the table; I will use this.
• The storage space will be in the form of draws and shelves.
Materials
• Durable wood is required as to avoid scratches and so it may last a long time, to get money’s worth.
• Silicon or cloth should be put under each leg to stop scratching against the floor and for support.
Customer
• My table is aimed at first time buyers, who will want a modern to design to fit in to a new house or flat.
Size
• This will most likely be used as a centre piece; the sizes should roughly be around 1000 long, 600 high and 500 wide. These are the dimensions of lots of modern coffee tables made at the moment.
Health and safety
• The first time buyers may have kids or will get kids, so there must be no sharp edges and it should be stable so it does nottopple.
SPECIFICATION
INITIAL IDEAS 1
INITIAL IDEAS 2
INITIAL IDEAS 3
INITIAL IDEAS 4
DEVELOPED IDEA 1
The table could have either draws or shelves. The draws will
have holes so they can be opened by hand. On the shelf
design, the shelf could follow through to the other side and
wood could be placed in the centre, creating two draws; one
on each side. The table could also contain two different
woods in contrast to give a modern look. Draws and shelves
are both available as these were equally popular in my
survey.
The legs on either side must be thick enough to support
weight of any objects that might be placed on the top
surface, such as a laptop or lots of books. The construction
of this will be complex as a good finish will be required to
look as if the top surface is connected to the legs. The
rounded effect can be created by sanding. To increase the
height of the plane, the angle of the legs could be enlarged.
This means it will be higher off the ground and more ideal for
people who don’t want to use it to sit around. A glass pane
could even be inlayed into the top plane of wood. This
means that items in the draws could be seen, and a cover
may be required. In the design with the shelves, the shelf
could go through the other side of the wood so it is easier to
access from either side. This could be taken even further
and could lead to the removal of the central piece of wood
separating the two shelves to make one large one.
DEVELOPED IDEA 1 CONTINUED
Sustainability results show that carbon
is extremely ineffective to be
sustainable, whereas cherry or acrylic
are easy to sustain. Acrylic is not a
likely contender for the material of the
table as it comes in small sizes and will
not cover the whole top with a 1m
sheet, and it is not stable enough. The
table will be roughly 1.6m x 0.5m x
0.4m, or possibly more if it seems quite
low in height and the leg height is
increased.
This design has rounded edges so it will be ideal for first
time buyers with small children who will not be in
danger. One shade of wood is preferred as it will look
aesthetically pleasing, as it can matches with
modernistic styles and will compliment a room well. It
also contains curved and straight lines which was
favoured from results in the questionnaire.
The curve on the table
top can be constructed
using bendy ply, which is
easy to get hold of and is
cheap; and therefore is
sustainable. The draws
look good on the design,
but shelves could be
used as a replacement
as the questionnaire says
either is popular. It is also
square so this also helps
as first time buyers may
have limited space and
want to put it alongside a
wall. Overall this is a
good design to take
forward as it meets the
spec well, but I may have
trouble getting the correct
angles on the draws.
DEVELOPED IDEA 2
The wood could even be curved to
give a more modern feel. Pads
should also be put under the legs to
stop scraping with floor.
The central shelf could be
replaced with a draw, but this
might be quite difficult as the
dimensions must be exact.
The original design hasn’t
changed much but instead of
two shades of wood, I have
decided one will look much
better as it is more suited to
the modernistic style.
The glass pane will be rested
on silicon pads to stop it from
falling off. Glass is also
favoured to wood as it adds
another characteristic to the
design. The edges of the glass
would be rounded to be safe.
First time buyers will have
small children and safety is
key.
In this wood touching the floor,
measurements must be
extremely precise so that it is
symmetrical and so that each
shelf has the same amount of
space for items.
The design could be made with draws
or shelves. The amount of shelves will
give enough space for magazines or a
laptop.
DEVELOPED IDEA 2 CONTINUED
The shelf sizes are big enough so that they will provide sufficient space for
books or remotes, but not too big as to make the table to big that it crowds the
room. Measurements on this design are key as if one side is wrong then the
whole table is lopsided and unsymmetrical. The angles of the two wood
planes for legs are also important as if these are off then the shelf going along
the centre won’t be horizontal and cannot lay flat against the side of one of
the legs. This central plane will be cut into three and then sanded at the end
to match the angle of the legs, so they can simply rest using gravity. If I leave
them unglued they could even be taken out so more leg room can be
achieved. However the middle piece must be glued as it would fall down if it
wasn’t.
To achieve the most profitable and
sustainable manufacture, injection moulding
should be done in Asia and should be
transported and used in Europe.
Ideally carbon fibre is the
best material to use for
the design. It is very light
and strong and would be
ideal against wear and
tear. But unfortunately it
is expensive to maintain
and will give a negative
profit.
Acrylic is very cheap and
can be mass consumed
extremely easily.
However, it lacks strength
and might suffer from
ravages of time. To add
to this, it is not a
popular material to use
predominantly as it
looks quite “cheap.”
Clearly cherry wood is a
good halfway point
between these two other
materials. Cherry is
inexpensive yet still looks
good and matches the
modernistic. Also a good
finish can be applied to
the wood to make it look
even better.
DEVELOPED IDEA 3
This is a very simple design providing a shelf
for items such as magazines and remotes. The
legs would go deep into the wood so that it is
stable. The wood can also be replaced with
metal, but will then be hollow to save money. It
provides storage with a simplistic style and
each part of the build can be separated. These
parts can be built individually. This makes it
easier to be mass produced as it makes
shipping and construction easier, reducing the
price. The piece of wood at the top would be
hollow so you can see through it to the shelf
below. This shelf could also be made of glass
but as it is not seen much it could just do with a
different shade of wood. A lighter shade at the
top and a darker one at the bottom.
This design should be smaller than the other
designs as it is circular and will take up more
room as it cannot be placed well alongside a
wall. This means it will not cramp the room.
The questionnaire suggests curved and
straight shapes are preferred so the table
could be turned oval shape with flat sides.
This means there would be up to six legs
in the centre.
I have taken the original design and
changed the shape of the glass and
added storage underneath while
keeping the shape and base of my first
sketch.
These legs will be made of chrome and
will be symmetrically placed to look
better. To add a more modernistic feel i
could add another few legs and shape
them like the points in a pentagon.
This curved wood piece
would be built using
many strips of bendy ply
and gluing them side by
side while they wrap
around. However this
means the grain lines in
the picture would not be
there.
DEVELOPED IDEA 3 CONTINUED
Clearly the wood option is
very sustainable compared
to aluminium or carbon.
Wood is also much more
accessible and cheap. As
aluminium is much cheaper
than glass, the top can be
replaced with a sheet of
aluminium in the same
dimension as the glass
pane. However glass is
usually a better looking
option which will look good
against the wood top.
This design is more
complex than others as
working with two different
curves in the shape such
as a sphere make it more
difficult and sizes and
angles must be very exact.
Where the shelf is placed,
the wood is not and the
two halves must look like
they are of the same
shape. The tubes will be
placed inside the wood
which will be dug out using
a drill.
These sustainability results once again that cherry wood is a good material to choose as it can be
sustained easily and is also very nice looking. The manufacture should take place in Asia and be
used in Europe or America to maximise profits by being sustainable. This table is not as simple as
the previous one because it contains chrome tubes which will be more complex to sustain as it is
one more material to make and incorporate.
JUSTIFICATION
This design is very simple and provides a good amount of storage
underneath. However first time buyers may be looking for a
square design as it takes up less space and can be placed near
the wall. Also the wood cannot be easily bent twice to create a
spherical shape.
This is a good table for first time buyers because it is made of
mainly wood, making it easy to manufacture and sell to people
with tight budgets. It also contains a large amount of space for
placing books or remotes. I could even replace the shelves with
more draws. The top is a pane of glass and could have rounded
edges to be safe for small children.
This design is excellent to be placed next to a sofa as it is low
down and can be reached easily. This may not be ideal for first
time buyers as they may not have a sofa as money is short. On
the contrary this design contains both curved and straight lines,
which was the most popular on my questionnaire. It will also have
a fine finish to keep the wood from being scratched.
This is my chosen design. This is because it is suitable for first
time buyers as it contains sufficient space for magazines etc., is
modernistic and simple and therefore easy to manufacture, and is
within the set dimensions.
MODELLING
I made this model by cutting card and acetate using a scalpel. This has been helpful as it
has shown me how the table balances and where it should be supported. All the weight is
on the two bottom pieces of wood, so these must be thick to stay strong. The scalpel used
to cut these it difficult to use precisely and that is why it is slightly askew. This proves how
important it is to get angles and lengths correct in the manufacturing process.
This is another angle of the design and you can see how the shelf running through the
middle relies on the legs being precise and at the correct length. I realize now that the wood
legs must be angled at the bottom so they can create the “v” shape on both sides. They
must also be the same so it horizontal. I think the middle shelf should be made out of glass
to match the top.
Here you can see a close-up of the legs. They are bending here as there is a lot of force on
them. If they are not made precisely this table could be unsafe and especially with young
children, this would not be good. Once all this has been achieved can the glass be placed
on top, with silicon pads to protect it and to stop it from slipping which would be bad as first
time buyers obviously do not want a table that will break.
QUALITY CONTROL
An array of features has been inlayed into the
design of my table, to ensure that it is easily
mass produced.
To join wood at a certain angle I have used a
jig for the 11 degree angle at the base of the
table.
To ensure that the draw is as
precise as possible, I have
created a template that can be
copied to possibly replicate
another table. However the
gluing process may affect the
size of the draw, and so a
sander is needed to cut the
draw down to size.
PRODUCTION PLAN 1
Process Tools and
Materials
Method Time Health
and
Safety
Picture of
Result
Cut wood for
frame
Done by teacher Fill in sheet for desired sizes and
hand to teacher
20 minutes This is done by
a teacher and
therefore my
safety is not at
risk.
Angle wood for
frame
Adjustable square and
circular saw
Mark off which end of the wood
will be angled and set the circular
saw to the desired angle, and run
the wood through.
20 minutes This is done by
a teacher and
therefore my
safety is not at
risk.
Brush Polish all
pieces
Brush polish and cones
for the wood to rest on
and paintbrush
Brush polish evenly across the
wood until it no longer glazes.
30 minutes
and 10 to dry
Wash hands
after using
brush polish
Wax all pieces Wax polish and cloth Using a cloth rub wax polish
evenly across the wood.
30 minutes
and 10 to dry
Wash hands
after using wax
polish
Strip wood
where glue will
be placed
Chisel Run the chisel across the area to
be glued stripping the polish and
wax off.
10 minutes Chisel
downwards to
avoid cutting
something else
Glue wood
bases
PVA glue and clamps Add glue to wood edges and line
up on a bench, using clamps to
keep them in place.
20 minutes
and 24 hours
to dry
Don’t get glue
on fingers
PRODUCTION PLAN 2
Process Tools and
Materials
Method Time Health
and
Safety
Picture of
Result
Glue wood
shelves
PVA glue and clamps Add glue to shelf pieces and then
let them rest on base.
1 minute and
24 to dry
Don’t get glue
on fingers
Sand table
edges to align it
Orbital sander Use sander to flatten any pieces
sticking out.
20 minutes Don’t touch
sander and
wear goggles
Route draw Router Use router to make grooves for
draw sides.
30 minutes Wear goggles
Cut draw sides Band saw Run sides through for desired
length.
20 minutes Keep fingers
away from saw
and wear
goggles
Glue draw
together
PVA glue Put PVA in routed edges and put
sides in and leave.
10 minutes
and 24 hours
to dry
Don’t get glue
on fingers
Cut hole for
draw
Pillar drill and drill bit Attach drill bit to drill and then drill
down into the middle of the draw.
5 minutes Keep hands
away from drill
and wear
goggles
Rest glass on
silicon pads
and assemble
Silicon Pads, draw,
glass and frame.
Stick silicon pads on wood, then
rest glass on top.
1 minute Don’t drop
glass as its
heavy.
ORTHOGRAPHIC
CHOSEN DESIGN
EVALUATION 1
Function
• My design is aimed at first time coffee table buyers, or for couples moving into a new house. It will function as a regular coffee table, and should provide sufficient space for plates and cups to stand on top of.
• It will have space to comfortably store magazines, remotes or games.
• There are 2 shelves and draw to store big things like magazines and plates, and significant space on top of the table.
Aesthetics
• My table will be in the modernistic design style.
• I would like to make the table all one shade of wood, with dark or light.
• As my questionnaire shows, a mix of curved and straight lines is the most popular design for the outside of the table; I will use this.
• The storage space will be in the form of draws and shelves.
• The table I've created is modern, with a light shade of wood, however I did not include any curves in the design.
Materials
• Durable wood is required as to avoid scratches and so it may last a long time, to get money’s worth.
• Silicon or cloth should be put under each leg to stop scratching against the floor and for support.
• I have waxed and polished my wood in order to protect it. The wood can therefore be placed against a hard floor without damage.
Customer
• My table is aimed at first time buyers, who will want a modern to design to fit in to a new house or flat. The age range is 25-35.
• This table is cheap enough for first time buyers and can be placed against a wall comfortably.
Size
• This will most likely be used as a centre piece; the sizes should roughly be around 1000 long, 600 high and 500 wide. These are the dimensions of lots of modern coffee tables made at the moment.
• The table is a little over these dimensions as the glass has a small overlap, yet the width was changed to 300.
Health and safety
• The first time buyers may have kids or will get kids, so there must be no sharp edges and it should be stable so it does not topple.
• The glass has curved edges for safety and will not topple due to silicon pads. The table is secure.
EVALUATION 2
My table fits the brief on the majority, containing ample shortage space for many things like
DVD’s, magazines and remotes.
A modernistic style has been incorporated using glass on top to act as extra space for plates
or mugs.
The design also contains a draw for smaller things that can be put away. There is spare
space for books in the lengths at the bottom.
The table can be placed against the wall as it is squared. This makes it easier to put in a flat
that a first time buyer might have. However it retains its small size so can be placed almost
anywhere.
The production plan was a good start for my
table yet it was hard to follow as there were
many hiccups in the production of the table.
Gluing times made it difficult to keep the flow
of manufacture. One shelf had to be
hammered it using nails as it would not glue
without falling. Also the draw sides were made
of ply and not cherry as it was easier to
construct this way because they could be
routed easily. The draw was glued a little
wonky and therefore it had to be sanded to fit
in the frame. The glass also took a lot of time
to arrive and so I had to wait to take final
pictures of my designs. Some sided has to be
sanded so that they didn’t protrude from the
design.
EVALUATION 3
Quality control was a success. If I was
manufacturing on a large scale the jig for the angle
in the wood, and the draw can be used to replicate
the sizes for each.
If I were to do this project again I would add another
dimension to my design, possibly by adding more
draws so that there was one in each shelf. Also it
could be made with more accuracy, so that no
planning or sanding would b necessary. Finally
sketches would be made more precise.
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