UX Researcher, Parametric Designer, Industrial Designer, Optimization Engineer, Manufacturing Engineer
COLLABORATORS
MJ Mayo, Ian Backstrom, Greg Reeseman
CONTEXT
Furniture as a proof of concept for scalable, large-format additive manufacturing (LFAM).
A research-driven exploration of DFAM principles applied to furniture design—this collection investigates how LFAM can produce functional, customizable, and circular products.
Furniture as a proof of concept for scalable, large-format additive manufacturing (LFAM).
A research-driven exploration of DFAM principles applied to furniture design—this collection investigates how LFAM can produce functional, customizable, and circular products.
Key Insights
Circular design begins with controlling geometry, material, and process from the start.
Modern furniture design favors cost-effectiveness over longevity. Applying additive manufacturing to this sector offered a pathway to mono-material designs that reduce waste and extend product lifespans—all while opening the door for increased customization.
application
Parametric control enabled visually refined, fully manufacturable geometries.
I developed parametric algorithms that balanced form complexity with material efficiency. These algorithms generated continuous toolpaths optimized for polymer extrusion, factoring in deposition width, thermal management, and layer adhesion. The resulting geometries maintained aesthetic flexibility while staying within machine and material constraints.
I developed parametric algorithms that balanced form complexity with material efficiency. These algorithms generated continuous toolpaths optimized for polymer extrusion, factoring in deposition width, thermal management, and layer adhesion. The resulting geometries maintained aesthetic flexibility while staying within machine and material constraints.
Impact
An end-to-end demonstration of design automation meeting sustainable production.The project proved that LFAM could produce large, detailed furnishings at reduced cost and environmental impact. Its workflow seamlessly integrated generative modeling, simulation, and production, validating additive’s role in manufacturing at scale.
learnings + NEXT STEPS
Building stronger material supply chains is key to scaling circular AM in the U.S.
Domestic availability of recycled thermoplastic feedstock remains inconsistent, creating bottlenecks for circular LFAM adoption.
Building stronger material supply chains is key to scaling circular AM in the U.S.
Domestic availability of recycled thermoplastic feedstock remains inconsistent, creating bottlenecks for circular LFAM adoption.