jason cusack

MAW Furniture

A Table & Bench

project introduction

Named for their principal materials of maple, aluminum, and wenge, the MAW Bench and Table were designed with a unifying aesthetic, but were initially conceived as totally disparate projects. The bench was the product of a short, five-week course in seating design, while the table was produced about two years later for an independent study.

Spec Sheet

  • Student work
  • Bench completed Fall 2011
  • Table completed Summer 2013
  • Each built in approximately two weeks

Original bench concept sketch

Modified, final bench design.

  1. Wenge Comb
  2. Washer / Nut
  3. Maple Slats
  4. Aluminum Leg Structure
  5. Alloy Bolts

MAW Bench: Parts & Assembly

The MAW Bench's aesthetic guides the design of a matching table.

Translating the bench's slatted design (top) into a corrugated structure (bottom) achieves a lightweight-yet-rigid tabletop.

  1. Wenge Beams
  2. Maple Planks
  3. Wenge Inlay
  4. Custom Fasteners
  5. Alloy Steel Bolts
  6. Leg Structure
  7. Shelf
  8. Barrel Length

Table surface and leg structure are joined via sixteen custom-machined stainless steel fasteners (d).

  1. Custom Stainless Fasteners
  2. Wenge Inlay
  3. Maple Planks
  4. Wenge Beams
  5. Aluminum Leg Structure
  6. Alloy Steel Bolts

MAW Table: Parts & Assembly

A lamination of alternating planks & beams reduces weight without sacrificing structural integrity.

Interlocking boards apply even pressure whilst the adhesive sets.

Aluminum legs are tapered by milling each edge at a precise angle.

Before & after tapering.

Holes drilled into the upper rails will seat the custom stainless fasteners.

Finished leg components are TIG welded.

Fastener blanks carved from stainless rod on a CNC lathe.

A band saw trims blanks from stock.

Fastener heads are machined to final thickness.

A pentagonal drive pattern is milled into each fastener.

Fastener barrels are finally threaded to accept 5mm alloy bolts.

A bespoke tool secures the 16 fasteners.

jcusack@vt.edu

project introduction

Named for their principal materials of maple, aluminum, and wenge, the MAW Bench and Table were designed with a unifying aesthetic, but were initially conceived as totally disparate projects. The bench was the product of a short, five-week course in seating design, while the table was produced about two years later for an independent study.

 

Spec Sheet

  • Student work
  • Bench completed Fall 2011
  • Table completed Summer 2013
  • Each built in approximately two weeks

  1. Wenge Comb
  2. Washer / Nut
  3. Maple Slats
  4. Aluminum Leg Structure
  5. Alloy Bolts
  1. Wenge Beams
  2. Maple Planks
  3. Wenge Inlay
  4. Custom Fasteners
  5. Alloy Steel Bolts
  6. Leg Structure
  7. Shelf
  8. Barrel Length

  1. Custom Stainless Fasteners
  2. Wenge Inlay
  3. Maple Planks
  4. Wenge Beams
  5. Aluminum Leg Structure
  6. Alloy Steel Bolts

jc