For a school design assignment we had to design reconfigurable interior furniture. After a lot of idea iterations we developed a fun and ecological exposition wall. It consist completely out of corrugated cardboard panels and cardboard tubes. It uses easy to find cargo lashings, to tie everything together.
We used cardboard for two reasons: Cardboard is cheap and easy to find and can come in many different sizes and shapes. Second reason cardboard is very light, so storage of al the components isn't a problem.
The beauty of this design is the easily expandable nature. Simply add more panels and tubes to enlarge your wall! Completely customizable to the demands of the user.
This assignment was in collaboration with following designers:
Wiebe Van Gansbeke , Anton Lenssens and Robin Nys.
Step 1: Gathering the Materials
The bill materials is calculated for a kit consisting of 4 panels:
- Honeycomb corrugated cardboard 12mm thick.
In total we need enough for four corrugated cardboard panels. With a dimension of 1 by 1.5m.
We chose honeycomb corrugated cardboard for its thickness and strongness in both directions. This in contradiction to normal corrugated cardboard.
- Cardboard tubes around 68mm diameter.
Number and length depend on your setup. How you orient your panels, number of panels, placing two on top of each other, ....
Each setup will need its own length. lengths can vary between 1m, 1.5m and 2m
For a basic kit we will need 2 tubes with a length of 1m and 5 tubes with a length of 1.5m. So in total a lengt of 9.5m
Save any scraps you find, you will need them!
- Cargo straps
For a basic kit, you will need 16+ cargo lashings. Each with a minimal length of 2m.
Step 2: Gathering Tools
- A hole saw with a slightly smaller diameter as your cardboard tubes (-68mm)
- Drill press for drilling holes
- Table Saw
- A Spindle Sander or sandpaper
- Wood Glue
- Miter saw
- Pencil and measuring tape
Step 3: ---Honeycomb Corrugated Cardboard---
We will start with the corrugated cardboard panel
Step 4: Cut to Size
Get your corrugated cardboard and cut it into 4 panels using the table saw. The dimensions of each panel should be 1 x 1.5m.
Step 5: Mark the Center Points
Using a ruler and pencil, carefully mark the center location for each hole. In every corner two holes have to be drilled in total. The first drilled 7.5 cm of each side. The second 15 cm of each side.
Do this 4 times, in every corner once. For all four of your panels.
Step 6: Drilling Holes
Place your hole saw into your drill press. Now carefully drill the 8 holes in each panel.
Don't forget after each hole, to remove the residual disc from the drill.
Step 7: The Result
Now we have our panels cut to size, with all the holes drilled.
Step 8: ---The Cardboard Tubes---
Now we continue with cutting all of the cardboard tubes.
Step 9: Cut to Size
For a basic kit we will need 2 tubes with a length of 1m and 5 tubes with a length of 1.5m. Measure them and then using your miter saw cut them to length.
Save any scraps you find, you will need them!
Step 10: ---The Rings---
Now we are going to make some rings. Later these rings need to be inserted into the holes into the panels.
They are inserted in the cardboard panel to reinforce the hole, to make the panels more durable. So that the cardboard doesn't get damaged by the straps.
Step 11: Cutting the Rings
Now collect all your scraps pieces of cardboard tube. Now mark a straight line 18 mm from the side on a piece of cardboard tube. So when we put the ring in the 16mm thick panel, the ring will protrude 1 millimeter on each side. This is by design, again to protect the panels from damages.
You will need to cut 8 rings for each panel, 16 in total. you can always set up a stop block for easy cutting!
Step 12: Removing Burrs
Use the spindle sander to remove any burrs left by the saw. Sandpaper will also work.
Step 13: Testing the Fit
Test the fit between the cardboard rings and the holes. If they don't fit exactly, use the spindle sander to widen all of the holes.
Carefully, don't remove too much. The fit should be tight, not too loose.
Step 14: Inserting the Rings
Time for the glue up!
Use regular wood glue in the joint, in order to secure the ring permanently to the panel.
Do this for al of the rings in the panels.
Step 15: ---Straps---
For connecting the panels to the cardboard tubes we use straps. because the distance is not so great, we can slightly shorten the straps. Using scissors, cut them approximately to a length of 40cm.
Use a lighter to heat the end to prevent fraying.
Step 16: Setting Up an Exhibition!
To set up an exhibition wall. Take your panel (1) and connect to both sides a cardboard tube (2) using two straps (4).
Just make sure with the next panel you add, use the other holes to offset the straps so they don't intersect.just make sure.
The possibilities are endless! you can put panels on their side or on top of each other. maybe even hang them from the ceiling!