For a little over a year now, I've been chasing around some concepts about flat-pack design: its history, its widespread adoption, and design research into modern methods. Parallel to these explorations, I've been using a CNC router and digital file hosting to test out new methods of manufacturing. My first product, the Zip TIe Lounge Chair, went live on OpenDesk last May. Made from a half-sheet of plywood and 44 zip ties, it uses common industrial materials and a universal design language that can be digitally distributed and modified. It was my first open-source object. I was optimistic about its possibilities, imagining a future where Amazon would CNC furniture right in its distribution warehouses for same-day delivery.
I was lucky enough to have it crop up on a few design blogs and featured in Make magazine. Released for free under a Creative Commons license, it has accumulated 2,000 downloads over 10 months. Via social media, I found that at least two people have built one, in Barcelona and Ohio (both using makerspaces). The miserable download-to-build ratio (.09%) illustrates the trouble with truly open-source, digitally fabricated furniture: it's still a lot of work, using machines that are not widely accessible. The chair looked too severe, shaped by the machining method and material constraints. More than a few commenters took issue with the durability and aesthetic of the zip-tie fastening. Six weeks in a gallery show proved their point, as UV light and lots of sitters broke the ties across the front of the seat.Read More