Lecture Notes: 3D Printing a Designer Chair

Introduction

• Presenter's Initial Reaction: Nervous excitement at the sight of the Magis Spong chair.
• Chair Cost: Estimated at $11,000.
• Initial Thought: Perceived the chair as 3D printed. Later learned it was made using rotational molding.
• Objective: Attempt to 3D print a life-size working Magis Spong chair for under $11,000.

Seeking Help

• Contact with Joel: The YouTuber known for having one of the biggest 3D printers.
• Printer Issues: The Orange Storm Giga had multiple malfunctions, making it unavailable for use.

Networking and Collaboration

• Local 3D Printing Groups: Sought help from local groups but found no leads.
• Reaching Out to Gabe B., Slant 3D: Contacted Gabe, who runs a mass production 3D printing facility.
• Collaboration Proposal: Decided to work together to 3D print the chair in parts.

Legal Considerations

• Copyright Concerns: Acknowledged potential legal issues as the chair is a designer piece.
• Intentions: Emphasized that it's a personal experiment, not for sale, and respect for Magis Design.

Creating the 3D Model

• Initial Attempts: Used a silhouette from online, imported it into Fusion 360 for modeling.
• Validation: Visited a store in Portland, Oregon to measure an actual Magis Spong chair.

Printing Process

• Problems with the Printer: Various technical difficulties and misalignments.
• Shipping Logistics: Complicated by international borders; used a shipping service in Blaine, Washington.

Assembly Challenges

• Initial Assembly Issues: Mistakes in dowel cutting and epoxy application.
• Redoing the Assembly: Used CA glue and epoxy for a more stable structure.

Overcoming Problems

• Core Misalignment: Discovered errors in assembly, which were later corrected.
• Use of Spray Foam: Applied expanding spray foam for structural support.
• Lessons Learned: Importance of strategizing and not rushing the assembly process.

End Result and Testing

• Chair Assembly: Despite initial setbacks, the chair was successfully assembled.
• Cost: Total cost was about $636, still significantly under the $11,000 benchmark.
• Functionality Test: Successfully tested the chair, proving its functionality.

Conclusion

• Final Thoughts: Emphasizes satisfaction with the final product and hopes for no legal repercussions from Magis Design.
• Call to Action: Encourages viewers to support on Patreon for exclusive content.
• Acknowledgments: Thanks to supporters and top patrons.

Key Lessons and Takeaways

• Plan Thoroughly: Importance of planning and patience in complex projects.
• Collaborate: The value of seeking help and working with experts.
• Adaptability: Being flexible and ready to change strategies when necessary.
• Perseverance: Importance of pushing through challenges to achieve goals.

Questions for Further Thought

• How do large 3D printing facilities like Slant 3D maintain cost efficiency?
• What are the best practices for avoiding common pitfalls in DIY projects?
• How can hobbyists navigate legal considerations in similar projects?