27π (Bench)

The Idea

Many benches today are straight in shape, so it's hard to communicate with someone sitting on the other side of the bench. There exist some semi-circular benches, but those are mainly for decoration and not for sitting on. That's what encouraged me to come up with a bench design where everyone can talk to one another on the bench easily. This semicircular bench allows for that.

The name 27π comes from the circumference of the semicircle of the bench.

Preliminary Drawings & Mini 3D Models

Final Preliminary Drawings

After creating a rough sketch on paper of my ideas and a larger 1:4 scale rough preliminary drawing, I digital made this 1:2 scale preliminary drawing through OnShape. I also calculated the exact dimensions that each wedge would need to be and created a paper template so that I could easily replicate the same wedge shape over and over again when manufacturing.

(Above) 3D Modeling the Bench in OnShape and 3D Printed a Mini Model of My Bench Using the OnShape File

Manufacturing

Cutting the Wedges Using a Bandsaw

After buying two types of wood, 6/4th inch, and 5/4th inch, I plotted out the parts I would need on the wood with their dimensions using a pencil. Then I began the wood preparing process using the milling machine, planar, and table saw.

I used the paper template I had made to draw the shape of each of the wedges onto the wood.

I then cut the wedges using a bandsaw, which were a bit uneven, but I went in and sanded them so they all eventually became even in shape and size (seen through later images).

Top View

I cut out the large semicircle pieces using a jig saw. I drew the circles using a piece of string, a pin, and a pencil.

Bottom View

I also arranged the pieces roughly in their spots to check dimensions.

Cutting and Screwing on the Front legs & Wedges

I next cut the front legs using a table saw and screwed them on.

Wedges got screwed on from underneath.

Cutting and Screwing the Back Legs

The back legs were also cut using a table saw and then screwed on from the side. The legs were a bit flimsy, which is why I added supports and two screwed on each back leg instead of one.

Added Support in Between Front and Back Legs After Seeing Previous Issue

Final Result After Sanding and Applying a Tung Oil Finish

I sanded the whole bench four times with four different grits of sandpaper. I then applied two coats of tung oil, with time to dry in between each coat.

Some More Photos

Here's a Photo of it in the Majors Exhibition at RISD

Here's a Photo of it in my Sunroom at Home

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