Multi-Faceted Fireplace
Assembly system
Design meets fire
...meets T.V
...meets speaker
Objective
Design an assembly system for a unique fireplace featuring 26 distinct faces, each connecting at varying angles. The fireplace is also home to a flat screen tv, which is hydraulically lifted up/down, and a Bluetooth speaker.
The system should ensure accuracy, simplify construction, and optimize manufacturing processes.
A FIREPLACE, WITH POCKETS
Managing Complex Geometries
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The fireplace’s 26 unique faces required precise angular connections.
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To maintain accuracy, concave and convex connecting angles were extracted from CAD models.
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Custom plywood brackets were designed and slotted into pre-cut slots within the panels to maintain correct angles during assembly.
Joiner Ideation
Alignment Systems
Plywood Skeleton: Designed as the internal framework, each panel features a triangular keyhole cutout in the centre as well as holes for joiner pieces.
Steel Exterior: Each piece of steel was etched with a triangle key on the underside, which acted as a stencil for the ply key to be adhered.
Two alignment boards, clamped flush to the concrete slab to position the ply in the correct place
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Assembly Process
The brackets were screwed into their corresponding slots aligning each piece with it's partner.
MDF mock up panels were fitted over the ply to verify the fit before cutting the steel.
After refining the steel profiles in CAD, they were cut using the waterjet.
Ply wood keys were glued to the underside of each steel plate.
The steel plates were slotted into their ply mates. And secured with an adhesive
Testing and Prototyping
Joiners doing their job on the inside
MDF test fit before cutting the steel
Final
Outcome
The completed fireplace assembly system successfully met the project’s objectives, delivering a precise, efficient, and repeatable construction process.