the woodland waste light - wordpress.com

The Woodland Waste Light

Charles Clarke

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with

Charles Clarke

The Woodland Waste light aims to encourage conversation about sustainability through unique and thoughtful design by displaying a

product made from waste in the new Eden Project hotel.

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Content

7 Introduction9 Project Partners13 Critical Context13 TomRaffield:WasteStreams15 TheEdenProjectHotel17 Research17 EdenProjectMeeting19 TypesofWaste21 HotelResearch23 Design Process23 Prototype125 Aestheticoftheveneer27 Spacing29 Prototype231 Fixings

35 LaserPieces37 Cleats39 Prototype341 Pegs43 LightSource45 Frame46 Final Design48 Lifestyle Shots51 Product Use53 Product Manufacture59 BillOfMaterials64 Project Evaluation65 Partner feedback66 References67 Bibliography

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The project aims to create an innovative product using computer aided design using materials from Tom Raffield Ltd.

Created with Tom Raffield and The Eden Project, with Tate and Harmer Architects, the wall light is a collaboration between several like-minded organisations ultimately aiming to help educate and increase awareness about sustainability.

Introduction

9tomraffield.com

Tom Raffield are a company in Nanskerris, Cornwall designing and crafting steam bent furniture and lighting, selling to a global audience. Renowned for his innovative steam bending techniques, most recently featured on Grand Designs, Tom Raffield transforms solid wood into artistic, flowing pieces.

ProjectPartners

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edenproject.com

The Eden Project is an educational charity and tourist attraction in Cornwall. It provides a wealth of opportunity for learning, whilst being extremely sustainable in its operation. The Eden Project is currently planning a new hotel on-site, where visitors to the area can stay in what is hoped to be the most sustainable hotel in the country.

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Waste streams are a natural part of any manufacturing process within business. Tom Raffield has a very efficient manufacturing process, but there are still waste streams within the organisation. These waste streams are often recycled or disposed of responsibly, but this is not always the most sustainable use of imperfect material.

CriticalContext

TomRaffield:WasteStreams

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tateharmer.com

The Eden project is planning a new hotel on it’s site and is looking to collaborate with local businesses, charities and educational institutions. After approaching Tom Raffield and The Eden Project, I decided to set up a collaboration where I could curate a partnership with the aim of creating a piece of furnishing for the Eden Project Hotel.

The Eden Project Hotel

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A meeting with Caron Johnson (Sustainable Construction Manager at Eden Project) provided a clear direction for the project. Caron stated that the illuminated shingle effect was very desirable and would work well in the new hotel.

The product would reduce the waste streams of a local business and provide employment for local people, whilst also educating visitors to the area through conversation. This project, therefore, covers all 3 pillars of sustainability.

Regular contact was made throughout the project, allowing for idea generation and product application to be discussed.

Research

EdenProjectMeeting

The first meeting with Caron at the Eden Project discussing the brief and the requirements for the hotel.Renders and sketches were presented, and the details of the hotel were discussed.

A meeting with Caron and some of the team working on the hotel, along with Tracey Smith (Commercial Manager).The final prototype was presented and discussed, and its potential applications throughout the hotel.

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Ash Oak Walnut

Through primary research at Tom Raffield ltd, several waste streams were identified. One of the waste streams identified was the wood veneer used to create some of the lights. The veneer comes in long reels and is cut to length by the craftsmen during manufacture. Some of the pieces on the reel can contain knots or imperfections that would not pass quality control checks. Other pieces of veneer are offcuts from the reel This waste stream was ideal for use in a project as it comes in consistent sizes and is one of the most frequently used materials on the business.

The veneer comes in Ash, Oak and Walnut, and varies in length. The width and thickness are always consistent.

TypesofWaste

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Research was conducted in to current trends in the hotel industry. Top hotels around the world were studied and themes and styles identified.

There is a strong trend in hotels for natural materials and greenery. This gives visitors a welcoming feeling and creates a natural warmth within the building.

The sustainable ethos embedded in The Eden Hotel are naturally displayed through the form and colours of the building. Natural materials compliment these organic forms and tie in to the aims of the hotel: sustainability, education and a welcoming environment.

HotelResearch

Top hotels around the world use natural colours and materials to make a reception area light and welcoming

Expedia.comExpedia.com

Expedia.com Expedia.com

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The exploration of ideas and design features has been done through extensive prototyping.

A range of prototypes have been developed through the project. This prototype was built to test a variety of light sources and the effects each one had on the aesthetic of the light. It also identified some key areas of refinement in the design.

Prototype1

DesignProcess

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An aesthetic was created through the identification of the waste stream within the business. This aesthetic was presented to Caron at the Eden Project who requested a product be developed with this characteristic. The design process aimed to create a functional product which was engaging and beautiful whilst being scalable and profitable.

Initial ideas were sketched and then created using computer aided design to visualise concepts in a photo-realistic state.Using the illuminated shingles, the design developed in to a wall hanging light providing a warm ambient glow, perfectly highlighting the wooden veneer with its natural colours and shapes. Once an application for the concept had been identified, the design of the internal components and manufacturing processes had to be developed.

Aestheticoftheveneer

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The spacing between the veneer components determines the amount of light that comes through the shade. A rig was created to test a range of spacings and angles that the veneers could be arranged at. An angle of 15 degrees and a spacing of 50mm was the most effective positioning of the veneer. This positioning allowed enough light through to illuminate the immediate area, and the user could not see the backlight directly. This position also allowed light to enhance the tips of the veneers, producing unique and beautiful shapes and colours. This characteristic aims to draw the user’s eye and ignite thoughtful conversation.

Spacing

50 mm

15 degrees

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The second prototype focussed on the design details. The frame used traditional joining techniques and handcrafted components.

Key details of the design were refined such as the chamfers on the frame and the addition of the french cleats.

Prototype2

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As part of the sustainable message the light provides, a fundamental design feature of the light was that no adhesives were to be used in the manufacture of the product. This set a series of challenges within the design where components join and related to each other. The reason for this rule was to ensure that the product could be recycled or disposed of responsibly at the end of its life.

Attaching the veneer to the light forced me to extensively research the characteristics and functionality of many methods of joining. The veneers are attached to horizontal slats within the frame. This design feature allows any length of veneer to be placed on the light. This also ensures the lights are made in a consistent way and that an even amount of light comes through the shade.

Fixings

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The use of small nails ultimately became the most feasible way of attaching the veneer to the slats. Nails are extremely cheap at around 0.1p per nail. This makes production economically advantageous. The use of nails, therefore, allows for a very cheap repair if a piece ever gets broken. The incentive to repair will discourage the disposal of the product, making it more inherently sustainable. At the end of the product’s life, the materials can all be separated, and the nails recycled.

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During prototyping, laser cut ply was used to test various angles and spacings for the frame.Through prototyping and testing, the most effective combination set the angle of the veneer at 15 degrees at a spacing of 50mm.

The final frame has been designed to house the slats. This process will involve CNC routing the frame. This can be done directly by the manufacturer.

LaserPieces

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A stable, strong and secure method of fixing the light to the wall was required to ensure the light is safe to use and does not move from it’s position. Testing various methods revealed the most secure and stable method is the French cleat. This baton supports the product through angled faces and gravity, ensuring the product will stay fixed unless purposefully removed. One baton is attached to the wall, and the other is fixed to the frame and hooked on. Each light has two pairs for security and stability.

Cleats

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This prototype was the first scale prototype made, using an LED panel and some traditional joinery. It was tested in the showroom of Tom Raffield ltd and was used to gain valuable feedback from partners.

Prototype3

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The frame itself is secured without adhesive, using traditional joining methods. The corners are secured using butt joins and secured using wooden pegs. These pegs provide friction between the components and secure them together tightly. This join is very neat and subtle, ensuring the focus of the piece is on the veneer and its unique patterns.

Pegs

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The light source is a vital component of the product. The warmth, intensity, direction and type of light were all considered in the design process.

One of the most energy efficient types of light on the market is the LED. This type of light source uses very little energy and comes in a wide variety of colours and intensities.

This light source comes in standard sizes and is mass produced, making it economically effective for the light.

The panel is a 40 watt light with a long lifespan (30,000 hours).

A warm hue was chosen to accompany the natural colours of the veneer. The hue of the light helps accentuate the tones and reflects the homely feel I am looking to achieve.

LightSource

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2 3 The inside of the ash frame has slots positioned at the correct angle and spacing to allow the slats to be secured in to. The slats can then be taken out and reordered to suit the consumers needs. The ability to take slats out also ensures repairing the product is easy, as each slat comes out individually. This feature also allows for easy cleaning and maintenance.

Frame

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FinalDesign

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LifestyleShots Context Photo of the light in a home

Visualisation of a room in the Eden Project Hotel with the Woodland Waste

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600mm

600mm

300mm

300mm

ProductUse

The product comes in 2 sizes. A large version is designed for use in the Eden Project Hotel for decoration and function only. A smaller size is designed for sale at the Eden Project Shop as it is more marketable as a smaller version and can be made more frequently using the waste stream.

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ProductManufacture

The manufacture of the frame has been designed to be simple and cost-effective.The frame is made from white ash and is supplied and cut by a local hardwood specialist, where it is CNC machined to the correct specification. The frame can then be assembled easily using pegs to secure the joins, negating the requirement for adhesives.The frame is made up of 6 components, including the french cleats which secure it to the wall.

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The next step is to arrange the veneer offcuts on the slats.This process involves choosing different lengths and wood types and dispersing them on the slat in an interpretive manner. This process may provide an opportunity to involve a charity, where people can come and experience the workshop at Tom Raffield. This process requires minimal skill, making it ideal for initiatives working with people suffering from learning difficulties.

This could also provide an opportunity for the Eden Project to run workshops for visitors.

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Once the veneer has been attached to the slats, they can be inserted in to the frame. The slats are very easy to install as the machined frame includes slots at the correct angle and spacing.

The light slots in to the product once the slats and the frame have been manufactured. To install the light, the consumer simply secures the wall fixings in the desired location and latches the light over the batons to create the fixing.

For the Eden hotel, the light will be hard-wired in to the wall

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TechnicalDrawings

Material: English White Ash unless otherwise statedSurface fi nish: NoneGeneral Tolerances: Linear: 0.5mmAngular: 0.5If in doubt ask

ccWoodland WasteSPD

Proprietary and Confi denti al:The informati on contained in this drawing is the sole property of Charles Clarke. Any reproducti on in part or whole without writt en permission of Charles Clarke is prohibited.Unless otherwise specifi ed, dimensions are in millimetres.Scale references drawings at A3 paper size

Technical Drawing Complete

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Dept. Technical reference Created by Approved by

Document type Document status

Title DWG No.

Rev. Date of issue Sheet

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1/1Scale : 1 : 5Exploded Drawing : Frame

Charles Clarke

304-01

304-05

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Item Number Description Quantity Cost per unit (£) Machining Net Cost (£) Supplier304-01 Top Border 1 10 12 22 White Ash - Beech Brothers - Exeter304-02 Right border 1 10 12 22 White Ash - Beech Brothers - Exeter304-03 Left Border 1 10 12 22 White Ash - Beech Brothers - Exeter304-04 Bottom Border 1 10 12 22 White Ash - Beech Brothers - Exeter304-05 Cleat 2 4 5 18 Pine - Woodstock - Falmouth

304-06 Wall Fixing 2 4 5 18 Pine - Woodstock - Falmouth 304-07 Peg 14 0.1 2 29.4 Oak - Beech Brothers - Exeter304-08 LED 1 35 0 35 Beam LED304-09 Slat 12 0.70 0 8.4 Woodstock - Falmouth304-10 Veneer 96 0 0 0 Tom Raffi eld Ltd - Nanskerris

Total 196.8

BillOfMaterialsBillOfMaterials

Complete list of components, quantities, costs and suppliers of the product for a single order. This list is a breakdown of the product, allowing margins to be calculated and economies of scale to be implemented.


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Charles ClarkeMaterial: English White Ash unless otherwise statedSurface fi nish: NoneGeneral Tolerances: Linear: 0.5mmAngular: 0.5If in doubt ask

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ProjectEvaluation

This project had allowed me to create an extensive and valuable network of professional contacts, alongside developing my skills as a designer/maker. I have created meetings with architects and designers and had conversations with solicitors and charities. These people will be in my network for the rest of my life and could be invaluable in the future. The skills I have developed have been crucial to a successful project, with hand-built frames and craftsmanship playing a key role in the final prototype. I feel that this has been a hugely successful project for both my career as a designer but also as a professional and on a personal level.

Partnerfeedback

“It has been an absolute pleasure to work with Charles. From our initial meeting when we had a very positive discussion about what product to develop to seeing the concept develop into most wonderful lamp design it has been a privilege to be part of the process. Charles has acted with professionalism listened to the client brief and responded with a product that fulfils the brief, is beautiful and could easily become a commercial product. I do hope we get the opportunity to showcase his work in the hotel.

I am sure he will go on to do great things in the design world.”

Caron JohnsonSustainability and Access champion, Eden Project Hotel

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ReferencesBIEGELSEN, AMY. 2017. "6 Successful Crowdfunded Public Art Projects". CityLab [online]. Available at: https://www.citylab.com/design/2011/11/6-crowdfunded-public-art-projects/547/ [accessed 26 October 2017].

CHANG, ELLIOT and ELLIOT CHANG. 2013. "'Beads' Art Installation Made From Recycled Plastic Bags Pops Up in Israel". Inhabitat.com [online]. Available at: https://inhabitat.com/beads-art-installation-made-from-recycled-plastic-bags-pops-up-in-israel/ [accessed 26 October 2017].

DEFRA.GOV.UK. 2012. Wood waste: A short review of recent research. Available at: https://www.google.co.uk/url?sading-waste-streams-FINAL.pdf&usg=AOvVaw1OzARZPu9cWe6RdzESpbMy [accessed 29 October 2017].

FOYLE, JONATHAN. 2017. "Designer whose steam-bent wood products are ahead of the curve". Financial Times [online]. Available at: https://www.ft.com/content/7b0411b4-251b-11e7-a34a-538b4cb30025 [accessed 25 October 2017].

Serpentine Pavilion 2017 designed by Francis Kéré. 2017. Serpentine Galleries [online]. Available at: http://www.serpentinegalleries.org/exhibitions-events/serpentine-pavilion-2017-designed-francis-k%C3%A9r%C3%A9 [accessed 25 October 2017].

BibliographyEden Hotel - Tate Harmer. (2017, November 30). Retrieved April 13, 2018, from http://tateharmer.com/projects/eden-hotel/

Eden Project Cornwall UK. (2017, November 30). Retrieved April 13, 2018, from http://www.edenproject.com/

Tom Raffield No.1 Pendant. (2017, November 30). Retrieved April 13, 2018, from https://www.tomraffield.com/products/no-1-pendant

Expedia.com.sg. (2018, January 1). Retrieved April 24, 2018, from https://www.expedia.com.sg/Khon-Kaen-Hotels-Green-Hotel-Resort-Khon-Kaen.h12030832.Hotel-Information

SPACES, PROJECT. 2017. "Funding Sources for Public Art - Project for Public Spaces". Project for Public Spaces [online]. Available at: https://www.pps.org/reference/artfunding/ [accessed 26 October 2017].

Sustainable construction, buildings, materials - Eden Project, Cornwall. 2017. Edenproject.com [online]. Available at: http://www.edenproject.com/eden-story/behind-the-scenes/sustainable-construction-at-eden [accessed 25 October 2017].

chclarkedesign.com

[email protected](+44)7713897550

Charles H ClarkeSustainable Designer

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