BellowBench
A multi-stiffness carbon fiber furniture woven in one piece
BellowBench is a multi-stiffness piece of furniture created by weaving stiff and soft carbon fiber braids into a single structure, eliminating the traditional assembly process. To achieve this, a material library was developed specifically for furniture applications, using industrial testing methods to optimize both stiffness and aesthetics. A computational tool was also developed to enable a seamless workflow between CAD design and BOM generation, enhancing manufacturing efficiency. Additionally, a parametric user interface was implemented to allow custom designs through real-time 3D modeling feedback based on user input, streamlining visual prototyping and collaboration among stakeholders.
Bellow design enables a compressible furniture
Inspired by compliant mechanisms, BellowBench is designed to be compressible, allowing it to be stored in spaces of various sizes.
Computational tool for rapid custom design
A computational design tool was developed to facilitate design communication among stakeholders and allow end-users to create unique furniture by adjusting parameters with visual feedback. These parameters include the number of units, the length of each unit, the height of the arc, and the overall dimensions of the bench. In addition to custom design, modular fabrication was also a key consideration throughout the design process.
Material characterization
Material characterization was conducted by evaluating the mechanical performance of braided carbon and glass fibers through INSTRON bending tests. The test results inform material selection for furniture applications, considering both structural and aesthetic aspects.
Finite element analysis to assess mechanical deflection
To further assess potential mechanical deflection on final product, fine-element analysis was conducted through ANSYS simulations to provide product iteration guidelines (e.g., where to add materials to increase strength). In the simulation model, the composite was laminated, instead of braiding, to define thicknesses or volume. The boundary condition and forces were then applied to complete the simulation.
From CAD to fabrication: jig preparation and assembly process
To enable seamless translation between CAD and fabrication, we developed an extension for jig design and its BOM. For prototyping purposes, we used only off-the-shelf materials, so considering the standard dimensions of materials like styrofoam and paper sheets was critical to ensure effective material use. A step-by-step assembly process was visualized to guide physical prototyping.
A full scale prototype capable of supporting two adults's weight
Resin was applied to the final woven carbon fiber piece to enhance its strength.
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