Sef Nightstand

Programs Used: Rhinoceros and KeyShot

The purpose of this project was to bend concrete. After deciding to make a nightstand, I came up with different designs with the basis of the bended concrete being the table top and leg. After rendering many designs, I chose the one most suitable that balanced both aesthetic design with durability and strength. The finished product is very clean and sleek-looking, yet has a very interesting raw touch to it due to the concrete finish. It is a one-of-a-kind piece that you can't see anywhere else.

 
 
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Design Process

 
 With a general idea of what design I wanted, I made variations and chose the best one.

With a general idea of what design I wanted, I made variations and chose the best one.

 
 Final Design

Final Design

 

Fabrication Process

Machinery Used: Table Saw, Band Saw, Planer, Sanders etc.

Materials:
The concrete mix consists of:
Portland Cement, Sand, GFRC Ad Mix, Plasticizer, Fiber Glass, CSA Mix and Silica Fume
Wooden Leg Base:
Lenga Wood, Polyurethane Finish, Steel Rods and Epoxy

 
 1. For one of the table legs, I cut Lenga Wood to the correct dimensions and design.

1. For one of the table legs, I cut Lenga Wood to the correct dimensions and design.

 2. Using a yoga mat and some spare plywood, I made a jig and mold for the concrete.

2. Using a yoga mat and some spare plywood, I made a jig and mold for the concrete.

 3. I then sanded and put three coats of polyurethane finish on the wood.

3. I then sanded and put three coats of polyurethane finish on the wood.

 
 
 4. I poured concrete into the mold, but when I bent it when the temperature set, cracks started to form because it was too dry.

4. I poured concrete into the mold, but when I bent it when the temperature set, cracks started to form because it was too dry.

 5. Second attempt, I checked the temperature of the concrete every two minutes and decided to bend it when it reached 80 degrees Fahrenheit.

5. Second attempt, I checked the temperature of the concrete every two minutes and decided to bend it when it reached 80 degrees Fahrenheit.

 6. after 24 hours of curing, I sanded it with the concrete angle grinder to obtain a smooth finish.

6. after 24 hours of curing, I sanded it with the concrete angle grinder to obtain a smooth finish.

 
 
 7. Due to the mat texture of the mold, the bended concrete finish was very rough and textured. A lot of mat was also embedded in the concrete and was very hard to remove. The corners were especially hard to remove as the power tools did not reach the inner parts. I had to hand sand it for a long time in order to get crisp corners.

7. Due to the mat texture of the mold, the bended concrete finish was very rough and textured. A lot of mat was also embedded in the concrete and was very hard to remove. The corners were especially hard to remove as the power tools did not reach the inner parts. I had to hand sand it for a long time in order to get crisp corners.

 8. After sanding the piece for more than 10 hours, the finish on the concrete improved by a lot and was very smooth.

8. After sanding the piece for more than 10 hours, the finish on the concrete improved by a lot and was very smooth.

 After completing the two parts, I drilled holes into both pieces to attach them together. I inserted steel rods in the holes and epoxied the rods into the holes. The two pieces then became securely attached to each other.

After completing the two parts, I drilled holes into both pieces to attach them together. I inserted steel rods in the holes and epoxied the rods into the holes. The two pieces then became securely attached to each other.