OTO: Chair making process and challenges

The process of making chairs in the OTO project
Material: Plywood (plywood)
Production steps
1. Software:
（1） Rhinoceros modelling: I use Rhinoceros software to model the chair and draw the shape and rough proportion.
（2）AI Conversion: I converted the model to Adobe Illustrator's three views, and adjusted the proportions to make sure it was accurate. I created four scenarios and proportions for testing samples.

2.Testing part:
（1）Sample test: Use the laser cutting machine to make different sizes and shapes of the samples, and select the most suitable size and shape by combining them, I use 4mm thickness of plywood, because there is a difference between the thickness of the samples (4mm) and the thickness of the real thing (18mm), which leads me to re-adjust the proportion of the whole, so that we can compare the effect more accurately and intuitively.
（2）Size adjustment: Considering the thickness of plywood and the possible error value of 3mm in the actual production, I made the size adjustment on AI to keep the adjustment space for myself.

3.Physical production:
（1）CNC cutting: 18mm thickness 600mm*1200mm plywood for CNC cutting.
（2）Sanding and assembling: Hand sanding and assembling the cut parts in the carpentry workshop.

4.Detail sanding:
（1）Machine Cutting: For some parts that are not completely separated by CNC, I need to carefully make extra cuts to avoid damaging the overall shape of the design.
（2）Hand sanding: Use sandpaper to sand the details as well as to make the rounded corners of the wooden strips, and use knives to sand the larger parts.
（3）Tongue and groove adjustment: I initially planned to use small wooden blocks of uniform length and width to hold the chair frame and side panels, but failed, so the technician taught me to use wedge construction, which snaps into the structure in the form of a wider top and a narrower bottom, and is ultimately very solid when struck with a hammer.

During the process of making, I encountered various problems, such as the difference between design and actual production, how should I anticipate at the design stage and solve the problems that may arise during the production process? How can I handle the challenges of the cutting and sanding process more effectively when faced with the characteristics of plywood? How can I flexibly adjust the design to suit the actual situation when encountering structural fixing problems? Thus every step from software design to physical fabrication tested my skills and creativity. I finally finished its physical creation through constant communication and testing with wood workshop technicians.