Prototype Production (Evaluation)

So this is the final design of my prototype chair.

Not all of it went to plan, but I am somewhat happy how it turned out.
Having to replace the backrest with plywood really did change the overall look of the final design, and did consume some valuable time.

However, the backrest feature works really well, and is easy to use and disassemble. The plywood does add some added weight to the chair.

 Overall the chair is quite structurally strong, and you can lean back and put heaps of weight onto the backrest and it will hold.

The chair can disassemble in different variations, and is quick to reassemble.

It takes approx 3-5 seconds max to assemble/ disassemble the chair.

This way to disassemble, I think, is the best way, and saves more space.

Prototype Production

Using a spray can, i sprayed the chair matt black.

I think this makes the plywood stand out less from the steel.

Prototype Production (Seat)

To match the new back rest, I decided to ditch the suspended seat design, and use the rest of the Plywood to make the seat.

Here is the backrest and seat together.

Prototype Production

I was forced to resort to plan B, as welding the backrest together didn't prove successful.

Because the Tubular aluminium steel was too thin, welding it together put holes into the tubing.

With insufficient time to re do the whole process again using different steel, I decided to go and use a different material for the back rest.

I went to Bunnings and got a meter long sheet of plywood to use as the main back rest.

I basically used the same outline and shape of the original backrest.

After cutting out the outline i used the left over aluminium tubing to use as the supports to hold up the back rest.

Prototype Production

I have started production on my prototype.

Here are the materials I am working with - Tubular steel x4, Steel rods x4, steel bar x8, Aluminium Tubing x2

I was quite lucky in purchasing my materials from a steel fabricators near my house and they offered my some good prices for the steel and also in cutting it.
I purchased the aluminium tubing (for the back rest) from Bunnings.

This is the overall measurements of my chair.

 With some assistance, I welded the steel bars together and then welded the steel tube to form the frame of the chair

 I then welded the steel rods to form the support

Then I cut the steel rods and welded them to create the sleeves for the back rest to slide onto

Further Concept Refinement

After Further concept refinement this is my final design.

Changes to the backrest, as in changing it from a sheet-metal back rest into a bent tubular steel frame, with perhaps maybe a leather strap of some sort to use as the support.

changed the seat into a suspended seat. and changed the design of the braces on the side of the chair.

Concept Refinement + Mock up

 

This concept had a sheet metal backrest that could be removed by inserting it into the slots of the tubular steel back legs.

the back rest would of been bent and folded into shape.

 Mock up of the concept