The brief aimed at the MODERNIZATION OF RATTAN, or the creation of a woven garden chair similar to traditional rattan products, but in plastic materials, with the following advantages: SPEED and LOW COST. Replacing natural rattan with plastic makes it possible to have a complete product faster and at a lower cost.
To create an interwoven garden set a detailed analysis of the weave type and surface decoration was carried out. In this phase the WEAVE TYPE and BEST MATERIAL to achieve the desired sculptural, tactile and aesthetic effect were decided. The key elements for creating the desired plastic effect (groove depth, weave pitch, depth sensation, etc. …) are analysed thoroughly using prototypes.
As a first step a 3D draft is made so the construction details for the final product can be analysed. In this phase, details such as the backrest angle, armrest volume and proportions, and seat spaces are analysed.
In the initial product study, particular attention is paid to studying the packaging and wrapping of the product for distribution in stores. Packaging analysis is crucial to define and optimize the overall dimensions, weight and related costs; all key details for shipping and product positioning by retailers.
INDUSTRIALIZATION OF PRODUCT TEXTURE
Surface effects, roughness and the details of the surface texture are analysed. Relief depths are studied to ensure they achieve the desired plastic and aesthetic effect. To produce a surface finish perfectly suited to commercial needs, a “pilot mould” was produced, constructed using exactly the same steel as the final mould. The pilot mould contained four equal weaving sections to be treated (using photoengraving) with four different texture depths.
One of the design’s strong points is its ASSEMBLY, which is modular and does not require screws; all the pieces that make up the garden set are assembled by interlocking, simply by applying pressure to the joints, which are fixed to each other thanks to the components’ automatic locking system. This system constitutes a SIGNIFICANT ADVANTAGE for end users who do not have to use screws or tools to assemble components. ASSEMBLY ANALYSIS: to test the effectiveness of this interlocking solution, some components were pre-assembled in the production department to simplify and streamline the assembly process for the customer.
Prototype verification involves examining all the relevant factors associated with the product: ease of assembly, structural verification to check support, checks and aesthetic checks. These verification operations are key because they enable identification and correction of any anomalies. This avoids subsequent and costly modifications to the moulds.
The product has the advantage of enjoying excellent stability and strength, although it is assembled WITHOUT SCREWS or tools. The article is assembled very easily and quickly. This is thanks to intelligent coupling and anchoring solutions, entirely designed and developed by our team. The INDUSTRIALIZATION process takes into account the production materials and required weight and the plastic thickness is consequently unevenly distributed. Given the large dimensions of the components, it is important to foresee production differences; for this reason, the drafts for the load-bearing structure and the weaving were treated unconventionally and inserted variably, diversified according to zone.
The FLOW ANALYSIS for filling the mould forms enables definition of the production cycle, i.e. how long it will take to produce one piece. Filling analysis allows to optimize the time necessary for product creation and therefore limit production costs. This analysis is carried out using sophisticated equipment and scientific calculation methods to obtain the right balance between heat levels and the propagation time of the material inside the mould.
At the end of the first mould test, small adjustments are made to the pressure of the hooks for insertion and the article is ready for definitive production.