Design Technology HL Example 7 Out of 9 Work

Design project 6 (HL): Outdoor seat
Criteria A - Analysis of Design Opportunity

Problem Analysis
Urban Heat Islands (UHI), being urban and heavily built-up regions having higher average temperatures
and temperature increases than surrounding sub-urban and rural areas, are becoming an increasingly
large problem in cities around the world. (Figure 1) Key causes of UHI include high carbon emissions, lack
of vegetation and airflow, and large amounts of concrete and dark surfaces.
Largest effect on most heavily urbanised

areas
Almost everywhere, except parts of Africa,

affected by UHI
Problem increases as global urbanisation

and climate change accelerates
Figure 1: Intensity of UHI around world (Source: National Natural Science Foundation of China)
As seen above, the UHI effect affects my home country of Australia, particularly in the biggest cities of
Sydney and Melbourne Denser Western Sydney's temperatures increased most
In 2014,
Melbourne's
surroundings
were >4°C
cooler than
city centre.
Figure 2: UHI effect in Melbourne Figure 3: Temperature increase in different areas of

(Source: Monash University) Sydney (Source: The Sydney Morning Herald)
Both cities' governments are attempting to combat the effect, as are local governments in urbanised
regions globally. With carbon capture strategies the most effective at reducing the UHI effect, Melbourne
City Council has promised to plant 3,000 trees a year to absorb CO2 in the area. Vegetation plantation is
the most common UHI-reduction strategy. However, this doesn't apply to all regions.
An interview with Senior Sustainability Policy Officer, RW, from City of Port Phillip, Melbourne, has high-
lighted Acland Street Plaza, St Kilda as one of public space "where trees are not an option" for counteract-
ing UHI due to concrete surfaces (Figures 4 and 5). Hence, other innovative solutions are required.
Only
greenery
in plaza
is two
trees
Figure 4: Acland Street Plaza Map Figure 5: Heavily concreted Acland Street
(Source: Port Phillip Council) Plaza (Source: Primary Research)
1
Design technology teacher support material 1

Design Opportunity
A solution needs to be designed where carbon offsetting techniques, such as greenery, can be
functionally incorporated into Acland street Plaza to aid local government initiatives to reduce the UHI
effect.
Seating is also an identified problem in the plaza, following observation. Interviews with Port Phillip resi-
dents highlighted the seats as unappealing or inconvenient. A carbon offsetting eco-chair will be designed
to address both issues.
Environment Analysis To road To tram

Acland Street Plaza is used as
a thoroughfare and a public Large amount Pedestrian only
space. of concrete area
increases UHI
The final stop of the popular Lots of circles
effect
number 96 tram line is on one in Plaza
end of the plaza, and the area architecture
Shade
receives 30,000 visits by tram Seats
coverings
each week. Figure 6: Acland Street Plaza Shop
Fronts
Findings from Acland Common seated activities

Street user observation • Reading newspaper
(60 mins/Pre-covid) • Looking at phone
• Eating
• Supermarket • Waiting
• Clothes shop
• Gift shop Average sitting time 20 minutes
• Cafes Common dynamic activities
• Pharmacy • Walking
• Banking • Running
Figure 7: Acland • Riding bike
Used as a walkway
High tourist area Street Plaza • Skateboarding
to nearby beach
• Roller-skating
Customer Analysis User Analysis

Target Audience/Customer: Port Phillip Council Target market/User: Port Phillip Residents, Particularly
St Kilda Residents
Customer Persona
User Persona
Name: Phillipa Porter Name: Steven Kilderson
Age: 40 Gender: Female Age: 34 Gender: male
Education: Bachelor’s degree Weekly income: $1,011 AUD
Employment: Port Phillip Location: St Kilda
Council City Planner
Bio Needs
Needs: • Not religious • Public transport access
• Satisfy public needs and wants • Rents house to get to work
• Meet state environmental standards • Politically left-leaning • Access to shops
• Economically feasible improvements
Likes
Priorities for adoption of new products: • Modern design and architecture
• Price • Environmentalism
• Functionality • Trends/unique design
• Environmental benefit • Public transport access to get to work
• Appeal To Residents • Access to shops

Market analysis
Seating options at Acland Street Plaza (Source: Observation, primary research)

Product
Aesthetics Simple Simple Simple Circle Simple

Circle Circle Circle Sleek, modern Circle
Wood faded Wood faded Greenery adds design Light colours
appeal
Large amount of
dirt is unartrac-
tive
Environment N/A N/A Tree and green- N/A Large amount of
ery in centre of materials, not en-
ring vironmentally
friendly
Function Seats 1 Seats 1 Seats several Seats 1 Seats several
people Has arm rests people
Safety No corners No corners No corners Corners round- No corners

ed for safety
Size Diameter— Diameter—1m Diameter—2m Width—70cm Length—>4m

63cm Height—45cm Seat width— Height to seat— Height to seat—
Height—45cm 50cm 44cm 46cm
Height—44cm Height to top— Diameter of each
73cm circle—1m
Material Concrete Concrete Concrete Concrete Concrete
Wood Wood Dirt Wood
Metal Metal Plants Metal
More Ideal The market for outdoor furniture products is

environmentally position significant (figure 8) meaning, if successful, the
friendly target audience of this product can be expanded.
Increasing market trends to prefer
environmentally friendly product could increase
demand.
Less More
functional functional
Less environmentally friendly

Figure 8: Perception map Figure 9: Outdoor furniture market size (2018)
3

Design brief
Design goal
The goal is to design and manufacture a high-fidelity one-off 1:1 scale prototype of a two-person chair
that incorporates CARBON OFFSETTING into the design while still being fully functional. With a USP of
offsetting carbon emissions in the area through pants and organic material, the chair will work with other
local government initiatives to reduce the UHI effect, with short and long term effects. The client is Port
Phillip City Council (target audience) with the intended market trial being Acland Street Plaza, with po-
tential implementation in other locations. The target market is Port Phillip residents AND TOURISTS,
specifically those in the suburb of St Kilda.
Success Criteria:
• Offset the effects of UHI by using green or organic materials
• Aesthetically pleasing
• Functional for use by the 5th—95th percentile of adult men and women
• Comfortable for average sitting time of 20 minutes
• Durable to outdoor conditions
• Manufactured using school design workshop equipment or local manufacturing
• Prototype must be produced within 3-4 weeks
• Prototype must cost no more that AUD$700
Design specification
Specification Rationale Testing method
1. Functionality 1.1 Must provide Most chairs in Acland Street Plaza either sit User testing
(Source: seats for al least 2 one person, or can seat over 6.
Observation, people There is a need for a medium sized chair,
interviews that can fit 2 or 3 people. Observation shows
1.2 Vegetation User testing
with Port about 60% of people who use the plaza are
should not interfere
Phillip with at least one other person, and therefore
with chairs function
council, a chair designed for multiple people is
secondary required. The 95th percentile of weight in
research) 1.3 Must hold the Australian men aged 18-65 is 110kg. User testing
weight of two adults Therefore, the chair must support at least Placing weights
in 95th percentile 220kg. on chair
2. Environmental 2.1 carbon-offsetting To successfully address the UHi effect, this Design analysis
(Source: material used, or chair must offset carbon, and not restrict
Secondary >1m2 of greenery airflow. If greenery is used, 1 m2 is the
research) minimum, which offsets about 0.2 kg of
2.2 the product carbon annually. If they absorb more carbon, Testing in
must not restrict the other innovative carbon-negative materials environment
airflow in any way could also be used. To consider other
environmental factors, minimal waste and
environmentally friendly materials used
2.3 Environmentally Materials
friendly materials testing
must be used Secondary
research
2.4 Material usage Design process
and waste must be
minimised

Specification Rationale Testing method

3. Size 3.1 The height to the Current seating in Acland Street Plaza has Design
(Source: seat should be height of 450mm ± 15mm, suitable for measurements
Competitor approx. 45cm 5th-95th percentile users. The largest seat's
analysis) diameter is over 4m, with this too large. Seat
3.2 The length of the must be small enough to not restrict walkway, Design
seat should not but large enough to ensure sufficient measurements
exceed 3m clearance.
4. Durability 4.1 The product A more durable product if more Materials

(Source: Port must be durable for environmentally and economically beneficial, testing
Phillip Council, >15 years with a longer life span resulting in less waste
secondary and cost over time. Current Acland Street
research) 4.2 The product seats are made of concrete and wood, and Materials
must withstand hence durable for 10 years. To compete, this testing
outdoor conditions product must be more durable than this, and
able to withstand outdoor conditions, Testing in
including heavy rain, wind and UV sunlight. environment
5. Aesthetics 5.1 Must be trendy Data from most recent (2016) census reveals User feedback
(Source: and unique average age of St Kilda Residents is 34, with
Secondary over half of residents being aged 20-40. This
research, target 5.2 Must fit with the younger target market must be catered to User feedback
market current pale regarding aesthetics. ST KILDA TRENDS Also, Testing in
interviews) concrete colours of current designs of the plaza, with light grey and environment
plaza circles featuring heavily, must be considered so
5.3 Must incorporate my product doesn't clash. Also, light colours User feedback
circles or curves don't absorb heat as much, hence helping Testing in
reduce UHi effect environment
6. Comfort 6.1 Must be Following observation, most people sit in plaza User testing
(Source: comfortable to sit on for up to 20 minutes, while waiting for User feedback
Observation) for 20+ minutes someone, or checking their phone. Chair must
hence be comfortable for this time
7. Cost (Source: 7.1 Commercial cost Port Phillip Council funding is distributed over User feedback
Interview with must be below various council facilities, so product cost must Market analysis
Port Phillip AUD$1800 be as low as possible. However, as this product
Council, will have desirable USP, the cost can be higher
Competitor than competitors.
analysis)
8. Safety 8.1 No sharp Many people ride on bikes, skateboards and User testing
(Source: corners roller-skates through the plaza.
Observation) Therefore, the chair should not be a safety
hazard. Also, allergies should not be activated
8.2 Plants used by the vegetation User testing
must not increase Secondary
risk of allergies research
9. Manufacturing 9.1 Prototype able Local manufacturing reduces required transport Design process
to be made in and packaging, meaning the overall
school or local environmental impact is less.
facilities

Key for annotations:

Green—Positive
Criterion B—Conceptual Modelling
Red—Negative
Initial ideas Black—Neutral
Small individual seats Seats at least two

Greenery on top of surface;
on greenery Art Deco people
lots of surface area
inspired
Geometric or
organic base
shape, options
Seats in middle are

unreachable and Seats lots of people, Plants placed under
unusable depending on no. of seats chair don’t get sunlight, will die
Modern geometric Plants on back of Log flattened at top for

Repurposed log;
angular design chair seat
reusing natural
materials
Plants inside
hollow; don’t
Flat at get sunlight
bottom Lengthened to sit Log will mould and
Only seats 1 despite large —will die
two+ people decay over time
size; lots of material used
Modern geometric angular Plants on roof,

Single sheet Can provide
design Individual wooden planks back and below
of material (minimal)
bent into chair, large cover from
shape, surface area rain and sun
modern
Nowhere to put plants Minimal structural supports, could fall

or bend and deform
Similar to current Plants on top; large surface area Art deco inspiration Unoriginal design
shade covering on back of
chair
Provides cover
from weather Biomimicry—
inspired by a
Blends with tree
surroundings Plants on
Swing; fun, but safety concerns reverse, distract from art deco design
Plants on top stair and sides,

Large, restricts Plants on each Inspired by steps, modern
large surface area
airflow, lots of ring above geometric design
materials bottom, large
surface area
Unoriginal design,
Seat on bottom ring, many people can sit Large, restricts airflow bulky and unattractive 6

Develop and Refine Ideas

Developed idea 1
Carbon-offsetting material
Developed Idea 1—Sketches and Measurements (e.g. mycelium) could be
used for seats
Iteration 2: Organic
Individual circle seats
Seats 8+ depending shape blends with
on bed of 140cm 140cm
on no. of seats current circle-based
greenery
around edge furniture
Iteration2: more circles

in middle, less green
No seat backs; space
45cm
reduces comfort 260cm
260cm Individual seat dimensions
Iteration 1: few circles in 40cm
Iteration 1: sharp corners Large greenery
middle, more green space
on rectangular bases surface area
As both iterations have flaws and benefits, both will be prototyped
5cm
Developed Idea 1—Cardboard Prototyping (2:1 scale)
Seat arrangement options
Fits more seats More greenery Seat in middle adds
Base could interfere
aesthetic
with users’ legs,
appeal
reducing
comfort
Less greenery
Option 2: Seats only
Option 1: Seats only Less greenery Option 3: Some seats in centre, half
around edge, half off base
around edge, fully on off base
base
Base shape options Organic shape goes
Option1: Rectangular shape better with Acland Option 2: organic curved shape
Appealing Street Plaza
contrast furniture
between
curves and
angles Less
space:
Potentially cramped
Long: takes up
sharp a lot of space, Can be shortened
corners lots of material in iterations
Developed idea 1—Prototype testing
Leg arrangement Bench tips when

option 1: legs in weight on each
centre side unequal Legs best
positioned
equidistant
to evenly
Middle sags under
Leg arrangement distribute
weight, not
option 2: legs at weight
practical for
corners heavy plants

Developed idea 1—Greenery

Greenery area calculations Greenery functionality
Large greenery area

means extra carbon
Large amount Greenery improves offsetting material
of greenery aesthetic appeal unnecessary
If greenery grows
high, could cover
and interfere with Can increase seat
seat height and use low Will reduce
growing plants interference of
plants with seat’s
function
This chair would have a greenery area of approximately 2.8m2.
The greenery would not interfere with the seat’s function, if the seat heights were increased.
Developed idea 1—Assessing against Design specification
Functionality Environmental Size Safety Manufacturing

1.1 Space for 2.1 At least 3.1 Height to 8.1 No sharp 9.1
2+ to sit
✓ 1m2 of
vegetation
✓ seat is
450mm
✓ corners
✓ Manufacture
feasibility

1.2 Vegetation 2.4 Material 3.2 No Total: 6/8
not interfering
with seat
✓ usage
minimised
 longer than
3m
✓ =75%
Developed idea 1—User feedback (St. Kilda residents)

Scored out of 10 (10=best)
Aesthetics User 1 User 2 User 3 User 4 Average
5.1—Trendy and unique 5 6 5 6 5.5
5.2—Light colours 4 4 5 4 4.5
5.3—Use of circles 7 8 7 8 7.5
Developed idea 1—Required future iterations Developed idea 1—Decision

- increased seat height Will be taken forward due to:
- Consider colours more - Large amount of greenery
- Reduce material - Strong aesthetic appeal
- Divide into smaller parts for manufacture feasibility - High potential to meet other specifications

Developed idea 2
Plants on top of shade covering: Large, uses a
Developed Idea 2—Sketches and Measurements large surface area lot of material
Inspiration: Street covering Plants naturally
currently at Acland Street Plaza watered by rain Not feasible
to
Roof provides protection
manufacture
from weather
with
available
Sits 3 people (2 on equipment
bench, 1 on swing)
Less flexible in arrangements

than current shade covering
Blends well with furniture Swing: fun and unique—

currently at Acland Street appeals to children Potentially unsafe, and
inaccessible to some
disabled people
Developed Idea 2—Cardboard prototyping (1:20 scale)
Greenery on top Very large
Large amount may be heavy, green area
of material for material must be
only 3 seats strong
Thin, doesn’t Greenery on
Bench seat is
interfere with top increases
long—no
airflow exposure to
underneath
sun and rain
support, Large base
potentially required to
unstable support structure
Increases
Could build structure into concrete: self-sustainability
expensive and potentially wasteful
Developed Idea 2—Prototype testing
Could create
diagonal
Lack of underneath support in
support means further
seat sags under iterations
weight
Decreases aesthetic appeal, ‘trunk’

potentially not thick enough to support
If user swings Swing is too

too high, unsafe, not
could hit feasible for
roof—safety production
hazard

Developed Idea 2—Greenery

Greenery Area Calculations Greenery functionality
Greenery may
be too heavy,
further testing Greenery on top
required of shade covering
Assuming
stability, greenery
doesn’t interfere
Greenery naturally with functionality
watered by rain,
minimising water
Large greenery area
usage
means extra carbon
This chair would have a greenery area of approximately 9.6m2 -offsetting material
unnecessary
This greenery would not interfere with the seat’s function, depending on weight
Developed Idea 2—Assessing against design specification

2+ to sit
✓ 1m2 of
vegetation
✓ seat is
450mm
✓ corners
✓ Manufacture
feasibility

not interfering
with seat
✓ usage
minimised
 longer than
3m
 =63%
Developed Idea 2—User feedback (St. Kilda residents
5.1—Trendy and unique 4 5 5 6 5
5.3—Use of circles 6 4 5 6 5
Developed Idea 2—Required future iterations Developed idea 2—Decision
• Increase stability of roof Will not be taken forward as:

• Remove swing • Potentially unstable
• Change colour • Not feasible for manufacture
• Increase support of chair • Low aesthetic appeal
• Improve aesthetic appeal • Too big
• Decrease size
• Divide into smaller parts to increase manu-
facture feasibility
10

Developed idea 3
Developed Idea 3—Sketches and Measurements
Inspired by Lots of sharp corners

Only seats
diamond one Directly flat back is uncomfortable,
shape doesn’t suit the human form
Modern and
geometric Extended to fit 2+
people Organic form,
works with circles
at Acland Street
Plaza Organic form inspired
by waves, referencing
Nowhere for plants to go: nearby beach
potentially on sides?
Plants could go on
back or sides, large
surface area Geometric design doesn’t
blend with current circle- No sharp
based furniture corners
Iterations are made
Uses a lot
to fix flaws and Carbon-offsetting material Plants could go
Chair back curved of material
develop design (mycelium) could be used on back using
for comfort
as a seat cover vertical garden
Developed Idea 3—Clay prototyping of iteration 3: Aesthetic prototype Could be made with carbon-
1:25 scale Solid model: uses a offsetting material
lot of material
Currently unfeasible to
create with school
prototyping equipment
Could adapt to modular

design to minimise size of
individual parts
Developed Idea 3—Prototype testing Seat curved for ergonomic

comfort
Can seat up to 4 Need to investigate

people anthropometric data to
(1:25 model and determine curve
figurines)
Potentially create non-slip
mat to place on seat
Seat is wide so
can’t lean back
Curved seat creates dip
for rain; reduces usability
Decreases user
comfort
In future Create drainage holes in

iterations, reduce non-slip mat
width of chair
11


Top of chair provides

gap between user
and greenery
Greenery
doesn’t
Greenery on back interfere
of chair with
seating
Vertical climbing
plants
Potential for greenery on the back of the chair calculated using the As greenery <1m2 carbon off-
equation for area of a triangle. setting material should be used
The chair would have a greenery area of approximately 0.8m2
The greenery would not interfere with the seat’s function Potentially carbon-offsetting
mycelium mushroom?
2+ to sit
✓ 1m2 of
vegetation
 seat is
450mm
✓ corners
✓ Manufacture
feasibility

1.2 Vegetation 2.4 Material 3.2 No Total: 5/8 =63%
not interfering
with seat
✓ usage
minimised
 longer than
3m
✓ 2.1 met if carbon-offsetting material used
5.3—Use of circles 4 3 5 4 4

• Incorporate circles more Will be taken forward due to:
• Reduce material • Aesthetic appeal
• Divide into smaller parts for manufacture • Ability to be adapted to meet other specifi-
feasibility cations
• Design mats to go on seats • Specification of 1.2 if greenery narrowly
• Increase vegetation, or use carrbon- not met
offsetting material
12

Developed idea 4
Can’t be manufactured
Developed Idea 4—Sketches and Measurements using available facilities
Single sheet of
Material material bent into shape
width: 5cm
Greenery on Could also be underneath
Sharp dangerous top and back seat, but would probably
corners, can die
curve in iterations Roof provides
cover from weather Only when rain/sun
Modern design (rain, sun, etc) from directly above
No supports,
Seats 2 people
potentially unstable Top and side unnecessary,
Sleek design wastes material
No seat reduces
reduces material
comfort
usage
Developed Idea 4—CAD prototyping (1:10 scale)
Option 1: Thin material, angled corners Option2: Thick material, curved corners
Material Thicker
Material thickness: material
thickness: 10mm (10cm is
5mm (5cm full size) stronger
full size)
Angled
Sharp Curved Thicker
corners add
corners corners go material,
to geometric
potentially better with more
design
dangerous circular waste at
Acland end-of-
Street Plaza life
Thin furniture
material, dematerialisation
and less waste Both iterations have flaws and benefits, so both will be tested
Developed Idea 4—Prototype testing

Exerting force on
Force exerted on prototype Prototype 1 shows its
to test strength easily deformed
Force exerted on middle

level simulates weight of Unable to support
users weight of users and
heavy greenery
Force exerted on top level
simulates weight of
Exerting significantly
vegetation
more force on
Prototype 2 shows its
St. Kilda is bayside stronger
suburb, often strong winds
Still deforms slightly,
Chair must not be further support could be
deformed by winds added to reduce
deformation
13


Limitation:
Greenery on
roof can’t be
Greenery heavy or will
doesn’t interfere deform
with seat
Model in 1:20 scale Greenery on

while figures 1:25 side of chair
scale
Vertical garden or
Anthropometric data used to climbing plants
ensure correct measurements
Carbon-offsetting mycelium
This chair would have a greenery area of 1m2 not strong enough to Could just be grown
The greenery will not interfere with the seat’s provide support on to structure?
function
Increase weight structure Increases overall
must support material usage
2+ to sit
✓ 1m2 of
vegetation
✓ seat is
450mm
✓ corners
✓ Manufacture
feasibility

not interfering
with seat
✓ usage
minimised
 longer than
3m
✓ =75%
5.2—Light colours 1 3 2 2 2
5.3—Use of circles 2 2 1 1 1.5
• Use lighter colours Will not be taken forward as:

• Reduce material used • Does not meet aesthetic specification
• Divide into smaller parts for manufacture • Large amount of material used
feasibility • Aesthetic specification of light colours and
• Create supports for roof circles not met
• Further testing at different sizes to test
stability
14

Material and Environmental Strength Hardness Durability Cost Aesthetics

Proposed (Secondary re- (Primary (Primary (Secondary (Secondary
application search) testing) testing research) research)
Pine wood— If grown Very high Low 10-15 years Cheaper High
chair base sustainably, good stiffness -paintable
impact, renewable -Light colour
natural resource reduces UHI
MDF— Bad Medium Medium 1-5 years Cheapest High
Chair base environmental stiffness cannot be -Paintable
Impact, harmful used outside -Light colour
binders used to reduces UHI
create sheets
Z-Ultrat— Bad impact, as Medium/ Medium 5-10 years Expensive Medium
Chair base destructive mining High cannot be -Modern
is required to stiffness used outside appearance
source resources
Poplar Ply- If grown High Medium 15-20 years Cheaper High
wood— sustainably, good stiffness -Paintable
Chair base impact, renewable -Light colour
natural resource reduces UHI
Silicone Bad No Low 20+ years Mid-range Medium
rubber— environmental stiffness -Paintable
seat cover impact, production (light colour)
of silicone creates
carbon dioxide
Mycelium + environmental Medium Low 20+ years Cheaper Medium
mushroom - impact; absorbs stiffness once hard- -Natural
Seat cover twice its weight in when ened -Light colour
CO2 hardened reduces UHI
Hessian Positive No High, but 5 years Cheap Medium

fabric— environmental stiffness weave easily -Natural
guides impact, as natural disturbed appearance
mycelium fibres, and
growth biodegradable
Proposed Carbon Offsetting Solution: Mycelium Investigation

Mycelium absorbs twice its weight in carbon annually and is more efficient at carbon offsetting than
greenery. Although soft and squishy when growing, once hardened mycelium can be used as a building
material in the chair when high compressive or tensile strength isn’t required.
Colour of final material when Mycelium grows into mulch, Quick growing time Somewhat unsmooth
outer layers fully grown inexpensive doubling of material natural surface
Mycelium bought Cut into 2cm Mycelium and sugar cane Condensation forms in tub, Can be sliced into
in 500g bags thick slices mulch layered in large tub 10 days later mycelium grows large sheets for use
15

Option 1
Mycelium can bd used to increase
Option 1—Changes made based on testing and feedback
overall carbon-offset
Scale: approx 1:20
Reduced greenery Seat attached to base with
Reduced to 3 area screws: joining techniques
Also improves
seats to reduce to be investigated
manufacture
material
feasibility
Modular design: seats/legs
Material: wood? can be replaced as required
- Plants may grow
into wood
Mycelium can be Unsmooth surface
Seat height used for seats potentially
maintained: low uncomfortable?
growing plants to be
Legs positioned under each
used
seat, where weight is largest Could be covered
with silicone?
Option 1—CAD modelling and iterations
A1—seats have Base and therefore A2—seats have More room for
no overhang greenery area reduced overhang over base greenery
Seats have More aesthetically

more support; appealing shape
more stable
Option A2 is better
as design is more
Base shape
appealing
not as visible
Sitting on edge where no Strong, stiff material can
support may deform chair be used to reduce this
B1—Chair raised from flat base B2—Chair sitting on open base

Greenery easily More complicated Greenery sits IN
grows and design; potentially base; doesn’t
interferes with unfeasible to interfere with
seat manufacture chair
Option B2 is
More material Potentially ring of
significantly
used mycelium or silicone
more
Looks neater
functional
Option 1—User testing
Seat diameter
of 40cm best
meets
specification
Seat diameter: 50cm Seat diameter: 40cm Seat diameter: 30cm

- too big - right size - too small
- Wastes unnecessary - fits all users - not suitable for upper
material percentiles
16

Option 3
Option 3—Changes made based on testing and feedback Mat required for comfort
High strength wood Scale approx 1:20
Made of required
Mycelium can be
interconnecting used as seat cover:
sheets of wood offsets carbon
Reduces material Sheets of wood

+ improves required too big for
manufacturer Makes design school laser cutter
feasibility unique
If mycelium used, Laser cut
plants not required. Orange and black pieces must be
Mycelium absorbs Plants still on back: Length reduced from used to note outsourced:
more carbon low surface area 160cm to reduce different direction expensive
material usage of wood
Option 3—CAD modelling
Slices stiff to join: no further 1:25 scale model
Fits two people
joining techniques Joins uncomfortable
required to sit on
Seat back height
Increases ability Seat and back too big to be
to be recycled could be covered laser cut, even
with mycelium when outsourced
Rubbish could
potentially be
Modular design: individual Back must be
shoved down gaps
pieces can be replaced as needed shortened
Mycelium mat could combat this Could curve up onto
Option 3—Iterations and further CAD modelling Rectangle indicated back, increases
potential mycelium aesthetic appeal
Back shortened for manufacture mat placement
feasibility, now 60cm Back no longer serves
as full back rest
Reduces material usage
Reduces comfort
Most chairs in Acland Street
All other measurements maintained
have no back rest
No backrest is not
Silicone mat over mycelium Unsmooth Mycelium mat placed across significant disadvantage
could increase comfort mycelium slices increases comfort and
durability and aesthetics uncomfortable design interest Climbing greenery can
grow on back
Somewhat unstable: but can Small parts can break,
be bolted to must be careful
the ground Lower
greenery
Smaller seat area than
still fits 2 option 2
Visually
Mycelium has same effect
appears Side armrest not evident when
as greenery, but amplified
wrong proportions sliced, decreased aesthetic
and comfort If Mycelium used, greenery
Dimensions can be altered
Could be built up out of mycelium unnecessary, reduced costs
in CAD iterations 17

User feedback (Port Phillip Residents aged 15-55)

Option 1
User 1 User 2 User 3 User 4 User 5
Positives Multiple seats, Green space Greenery good, Greenery is Unique and
greenery Circles feel appealing, ‘funky’ design
organic natural
environment
Negatives Poles under Sitting on plants Vegetation Users can’t face People can’t
chairs where uncomfortable, susceptible to each other easily talk,
feet go Seats isolated damage, can’t flower bed
sit in pairs requires regular
maintenance
Improvements Move poles, Bigger, room for Group 2+ circles Rearranging Put seats
wood material multiple people together so can seats together
per seat sit in pairs
Option 3
Positives Sturdy, unique Unique, Organic curves, Easy to Cheaper to

unobtrusive feels robust assemble, maintain,
design without being natural sturdy, looks
too solid materials like it will last
Negatives Low back Things could fall Only sits two Potentially Looks too small
down cracks people, damaged over
potentially time
uncomfortable
Improvements Increase back Add colour Incorporate More weather Increase size
size vegetation resistance and
protection
Comparison
Preference Option 1 Option 3 Option 3 Option 3 Option 3
Reason Greenery More functional Flowing organic Users more More inviting
shape, and connected,
allows people to simple
sit together assembly
process
Evaluation of feedback
• Overall, Option 3 is preferred for its functionality and design
• While Option 1’s greenery appeals, the seating arrangement is disliked
• Potential Option 3 changes based on user feedback:
• Create cover over wood for comfort, avoid things falling down
• Incorporate other colours
18

Final Decision and Justification Currently testable Specs

Specification Criteria 1. Functionality 1.1—2 seats
Option 3; the bench of interlocked wood panels
✓
1.2—vegetation not inter-
with a mycelium cover, will be taken forward. This
design meets the specification better than Option fering with function
✓
1. While Option 1 features visually appealing and 2. Environmental 2.1—carbon offsetting
environmentally friendly greenery, the size material or 1m2 greenery
✓
increases material usage and cost. Also,
2.2—not restrict airflow
functionality is limited by the isolated seat ✓
placement.
2.3—environmental
Although greenery is not be included to improve materials
✓
manufacturing and cost efficiency, mycelium is 2.4—material usage and
more efficient in absorbing carbon, and will have waste minimised
✓
greater impact on reducing the UHI effect.
3. Size 3.1—seat height is 45cm
Option 3 also received better user feedback, due ✓
to its unique and modern design, and the better 3.2—no bigger than 3m
functionality. ✓
4. Durability 4.1—durable at least 15
Poplar planks will be used for the chair base due
to its durability; treated and varnished to increase years
✓
hardness. The seat top and chair back will be 5. Aesthetics 5.1—trendy and unique
covered in mycelium to increase comfort and ✓
improve the environmental benefit. Also, 5.2—pale colours
mycelium's light grey colour suits the pale colours ✓
at Acland Street. As mycelium has an unsmooth 5.3—incorporates circles/
surface, a mat of silicone rubber will be added for curves
✓
comfort and drainage. The chair is too big to be
7. Cost 7.1—minimal cost
manufactured using school facilities, so the wood ✓
panels will be outsourced to a local laser cutter.
8. Safety 8.1—no sharp corners
✓
9. Manufacturing 9.1—manufacturable at
school or local facilities
✓
Final CAD model
Interlocking Red squares

wood panels indicate ideal
position of benches
in Acland Street
Mats can be attached to

mycelium with small tacks
Two hexagonal silicone

drainage mats
Mycelium cover adds height
Mycelium used to
create armrest
Layer of hessian underneath

for mycelium to grow in to
19

Criterion C—Development of a detailed design

Material justification
Material Poplar wood Wood is used for the base of the chair for its strength,
environmental benefits, and ease of use. Poplar wood was chosen
Component Wood Slices to for its affordable price, long life and availability at the outsourced
make main body laser cutter.
Environmental • Natural Material When Poplar is sustainably produced, it has a positive

properties environment impact. The tree is not endangered and hence
• Sustainable
production is sustainable. Also, the long product life cycle reduces
Production
material waste over time.
• Easily Recycled
• Durable
Physical/ • Stiffness and The stiffness and high compressive strength allows the chair to
working Compressive support the weight of users. As the material lasts 15-20 years, the
properties Strength product has a longer life than competitors. Treating the wood will
further increase this life span.
• Durability
Aesthetic • Light natural The colour of the wood fits the pale colours at Acland Street Plaza,
properties colour and will blend well. Also, the light colours mean the chair will not get
hot and further increase the UHi effect.
Material Silicon The mats allow a smooth surface to sit on, as well as providing
drainage for water to run off the chair when it rains. Silicon was
hence chosen for its water resistance and smooth, flexible
properties. Although silicon is bad for the environment, its long life
Component Mat
reduces its environmental impact
Environmental • Durable Silicon is highly durable, with a life of 20+ years, and more once
properties protected with paint and varnish. This means less waste is
produced. Also, as the unrecyclable silicon mats can be easily
removed, the chair base can still be recycled.
Physical/ • Flexible The flexibility of the silicon mean the mats will sit over the curves of
working the chair neatly, and flatten the potentially uneven surface of the
• Durability
properties mycelium to increase comfort, providing a smooth surface to sit on.
• Smooth texture As Silicon doesn't absorb water, rain will run off it quickly, increase
• Does not
functionality
absorb water
Aesthetic • Can be painted The red colour of silicon is unattractive and clashes with the light
properties coloured wood and mycelium. However, as the silicon can be
painted, it is spray painted a light grey and varnished for protection.
The varnish will also increase the hardness and scratch resistance
of the mats.
20
Material Mycelium The Mycelium mat is the key element of the design, as it is what
makes the chair carbon neutral and have an environmental
Component Top layer covering advantage. No other available material absorbs carbon dioxide at
the same rate, making it an innovative and successful material.
Environmental • Absorbs twice its As Mycelium absorbs a lot of carbon as it grows into the shape,
properties weight in Carbon the manufacturing process of the chair means it is carbon neutral,
Dioxide and potentially caborn negative, reducing the UHi effect of an area
when produced locally. Also, the durability of the material
• Durability
increases the chair's lifecycle.
Physical/ • Fire resistant Although the wood base makes the fire resistance of the
working mycelium irrelevant, it can prevent the chair catching on fire from
• Moldable when
properties the top (e.g. if a smoker accidently dropped a lighter) When
alive
mycelium is soft, it can be easily molded over the chair shape to
• Stiff and high com- create the desired shape. After it has grown and is left to die and
pressive strength harden, the high compressive strength means it is not deformed
when hardened by user's weight.
Aesthetic • Natural, pale grey The pale grey colour blends with the pale grey concrete furniture
properties colour. at Acland Street currently. Also, the natural, uneven texture
suggests the material is environmentally friendly, psychologically
appealing to the environmentally conscious target market.
Manufacturing justification
Material Mycelium Explanation
Marking out CAD model The mycelium is cut into sheets and molded by hand on the chair
base, following the guide of the CAD model to achieve the side
Making process Growing and back curve. This allows a high degree of manipulability,
Cutting into sheets creating the desired shape.
Moulding
Advantages Limited wastage The mycelium grown can be used to create the shape, with extra
used on the top or back to increase the size as required. This
High manipulability
by-hand method of manufacture allows the exact shape desired
to be reached, and testing throughout the molding process can
ensure the right dimensions
Design technology teacher support material 21 21

Material Poplar wood Explanation
Marking out CAD model and soft- CAD allows accurate models to be created, that can be sliced
ware to create slices and directly sent to manufacturing and laser cut.
Making process Outsourced to large

laser cutter
Advantages Low energy The laser cutter is automatic, and hence safer than manual
cutting methods. Also, the automatic nature means it is energy
Health and safety
efficient
Material Silicone Explanation
Marking out Paper prototype to The paper prototype allows a quick and accurate template to be
create template made on the chair base. The CAD drawing means can be directly
exported to the laser cutter
CAD drawing
Making process Laser cutter
Advantages Low energy As above, the automatic laser cutter increase safety and energy
efficiency in production.
Health and safety
595
460
565
990
70
98
215 66
460
22

Parts list
Part Part name Material Quan Length Width Height Process Finish
no. (mm) (mm) (mm)
1 Chair slice Z-1 Poplar wood 1 884 395 9 Laser cutting Varnish
8 Chair slice Y-1 Poplar wood 1 340 245 9 Laser cutting Varnish
18 Mycelium cover Mycelium 1 1000 550 250 Growing, N/A

cutting,
molding
19 Mat Silicon 2 290 400 4 Laser cutting Primer,
spray
paint,
varnish
20 Tacks Metal 35 12 2.3 - N/A N/A
21 Hessian sheets Hessian 2 1000 500 - Cutting N/A
23

Part diagrams—All measurements in millimetres
Mycelium cover
Front view
840
Silicone Mat
Side view
Top view
180
280
380
400
Chair Slice Y-1 Chair Slice Y-2
Side view Side view
245
242
422
450
8.75
340
Front view
Material width same
for all chair slices
8.75
As slice width < material
width, no joining method 218
needed
433
Using hammer, pieces can
be inserted into slice
9
Individual pieces can be removed
and replaced as needed
Scale: 1:10
24
Chair Slice Y-3

Side view
300
440
392
8.75
218
452
Chair Slice Y-4

Side view
288
450
358
8.75
454
Scale: 1:10
25

Chair Slice Y-5

Side view
Chair Slice Y-6

Side view
Scale: 1:10
26
Chair Slice Y-7

Side view
Chair Slice Y-8

Side view
Scale: 1:10
27

Chair Slice Y-9

Side view
Chair Slice Y-10

Side view
Chair Slice Z-1

Side view
Scale: 1:10
28

Chair Slice Z-2 Side view

95 8.75
215
197
198
188
180
175
83
177
168
442
348
245
715
985

86
133
107
181
175
210
174
177
203
192
205
449
412
112 110
572
985

94
120
177
182
177
206
179
195
210
210
435
422
130 562 123
985 Scale: 1:10
29

Chair Slice Z-5

Side view
90
117
175
182
175
211
205
178
195
210
350
437
420
130
128 564 121
982
Chair Slice Z-6

Side view
60
63
131
148
138
131
133
154
172
152
266
320
481
49
949
Chair Slice Z-7

Side view
94
77
60
76
71
78
75
68
158
189
Scale: 1:10
30

Assembly drawings
Chair Slice Z-2 Chair Slice Y-1 Chair Slice Y-2
Chair Slice Y-5 Chair Slice Y-4 Chair Slice Y-3
Chair Slice Y-6 Chair Slice Y-7 Chair Slice Y-8
Chair Slice Z-3 Chair Slice Y-10 Chair Slice Y-9
Chair Slice Z-5 Chair Slice Z-6

Chair Slice Z-4
• Hessian attached using

tacks at intersections
• Mycelium Mat laid over
hessian
• Mycelium grows for 1 week
• Mats placed on Mycelium Chair Slice Z-1
Chair Slice Z-7
secured with tacks
31

Plan of production
Process Task Equip- Quality control Risk assessment Time
ment
Order Mycelium ... ... ... 10 mins
prep
Material
Order Silicon ... ... ... 10 mins

Order Poplar wood ... ... ... 10 mins
Layer 3cm layers Saw, Ensure equal thickness of layers Be careful with saw, wear 10 days
Processing
Mycelium and mulch, apron, wear gloves

mulch in plastic con- plastic
tainer container
Laser cut base piec- Laser Ensure alignment Ensure particle extractor 70 mins
es (outsourced) cutter Check for gaps or movement on, wait to remove pieces
Laser cut silicon Laser Ensure alignment Ensure particle extractor 40 mins
mat cutter Check for gaps or movement on, wait to remove pieces
Varnish base pieces Wood Two even coats on each side Wear paint mask, work in 100
varnish ventilated area mins
Place parts Y-1—Y- Hammer Use level to ensure pieces fixed Ensure fingers are out of 40 mins
Assembly
10 in to Z-2 in place way of hammer

Place parts Z-3—Z- Hammer Use level to ensure pieces fixed Ensure fingers are out of 30 mins
7 into base in place way of hammer
Place part Z-1 into Hammer Use level to ensure pieces fixed Ensure fingers are out of 5 mins
base in place way of hammer
Attach hessian mats Hammer, Use tacks at intersection to Ensure fingers are out of 15 mins
to back of seat tacks avoid splitting pieces way of hammer
Tuck raw edge under for aes-
thetic appeal
Prime silicon mats Plastic Even coat on both sides Wear paint mask, work in 20 mins
primer ventilated area
Prime silicon mats Spray Two even coats on both sides Wear paint mask, work in 70 mins
paint Ensure edges are covered ventilated area
Varnish silicon mats Varnish Even coat on both sides Wear paint mask, work in 20 mins
ventilated area
Cut sheets of myce- Saw Ensure even, approx. 2.5cm Be careful with saw, wear 40 mins
lium thick sheet apron, wear gloves
Lay mycelium over ... Ensure no gaps in between Wear apron, wear gloves, 30 mins
hessian, shape sheets of mycelium carry chair with two people
back and sides Ensure side curve is strong
Cover mycelium in Cling Pierce film to grow mycelium Wrap and carry chair with 10 days
plastic film to en- film, Place weights on film so myceli- two people
sure growth weights um maintains shape
Leave in warm environment to
ensure growth
Remove film, place ... Place outside on sunny days to Dispose of plastic, carry 2 days
Finishing
chair outside ensure even hardening chair with two people

Secure silicon mats Hammer, Place tacks at edge of mats to Ensure fingers are out of 10 mins
to seat with tacks tacks maintain aesthetic appeal way of hammer 32

Criterion D—Testing and evaluation

Justifying testing strategies
Priority Outline of testing method Justification
Testing User Trial and feedback from target Receive qualitative data about the functionality
method market: Have 2 users sit on chair for 20 of the product; if the chair can sit two people
1 minutes, measuring dimensions of chair without deformation Receive qualitative data
before and after to note potential about the comfort and stability of the chair
deformation.
Testing Performance Testing: Apply weights to Gather further quantitative data regarding the
method product to test for instability or maximum weight the chair can hold so range of
2 deformation tolerance can be understood
Testing Performance Testing and User As restricted airflow increases UHI effect,
method Feedback: Place fan at one end of chair quantitative data about if the chair restricts air
3 and test to see if cool air can be felt from flow must be gathered to examine success at
opposite end. reducing UHI
Testing Performance Test: Pour water on product Determine how long after it rains until the chair
method to test water-resistance is dry and functionable, and hence test the
4 chair's functionality and resistance in its
outdoor environment
Testing Product Analysis: Measure height to seat, Ensure chair is within specified dimensions to
method and length of seat meet anthropometric requirements, including
5 sufficient clearance between users,
Testing Performance Testing: Place chair outside Test durability of product when exposed to
method for 2 weeks and observe changes in range of weather conditions to test success as
6 appearance. outdoor furniture product.
Testing User Feedback: Conduct survey of 10+ Determine if the aesthetic specifications have
method Port Phillip Residents regarding design's been met through gaining qualitative data
7 aesthetic appeal, uniqueness, and ability about the attractiveness of the product, and
to blend in Acland Street Plaza hence the product acceptance by target
market.
Testing Expert Appraisal: Interview client about Gain further qualitative data about the
method success of design and the price that aesthetics, and receive suggestion of price
8 would be paid. range this chair would be commercially sold at,
and hence whether this product would be
viable for commercial manufacture
Testing User Trial: Users walk in to chair Test if chair's corners are too sharp and
method repeatedly from different angles potential safety hazards.
9
33

Evaluating against Design specification
1. Functionality 1.1 Must provide place for at least 2 people to sit

1.2 Vegetation should not interfere with chair’s function
1.3 Must hold the weight of two adults in 95th percentile
Testing Strategy: User trial and Performance Testing
Strength: Two people can sit on chair, height to seat is comfortable,
comfortable for range of percentiles
Weakness: Vegetation not incorporated into design. If users lean back,
the chair unbalances and tips. Little room between users.
2. Environmental 2.1 At least 1m2 of greenery must be included

2.2 The product must not restrict airflow in any significant way
2.3 Environmentally friendly materials must be used
2.4 Material usage and waste must be minimised throughout the design process
Testing Strategy: Performance Testing, Material Research
Strength: Natural materials of Mycelium and Plywood very environmen-
tally friendly, air flow not restricted, Mycelium absorbs carbon more effi-
ciently than greenery would've.
Weakness: Reductive manufacturing technique of laser cutting produces
lots of waste. Cling film used for mycelium growing single use only
3. Size 3.1 The height to the seat should be approximately 450mm
3.2 The length of the seating should not exceed 3m
Testing Strategy: Product Analysis

Strength: Height to seat is 46cm, total length is 100cm, and seat length
is 92cm
Weakness: Although specifications met, the chair is too short, and users
are squashed closely together. Also, chair back is too short, making chair
look disproportionately small
4. Durability 4.1 The product must be durable for >15 years
4.2 The product must withstand outdoor conditions
Testing Strategy: Performance Testing, Material Research

Strength: All materials (Mycelium, Poplar plywood, silicone) have
lifespan of 15+ years. Design for disassembly, with all parts removable,
means parts can be replaced and lifespan extended. Materials withstand
outdoor conditions, particularly with varnish on wood.
Weakness: Paint on silicone scratches easily. Mycelium comes off in
areas where it has not fully grown into hessian. Testing done during late
winter, so durability during extreme weather conditions (sun, frost,
storms) not tested
34

5. Aesthetics 5.1 Must be trendy and unique

5.2 Must fit with the current pale concrete colours of plaza
5.3 Must incorporate circles or curves
Testing Strategy: User feedback
Strength: Natural curves incorporated, interlocked wood pieces and
geometric silicone mats create unique design.
Weakness: Mycelium didn't fully grow into mulch, creating unappealing
uneven brown patches. Colour of silicone mats doesn't match wood.
Etched numbers to identify pieces visible and unappealing.
6. Comfort 6.1 Must be comfortable to sit on for 20+ minutes
Testing Strategy: User feedback

Strength: Height to chair is comfortable. Sitting on chair is not
uncomfortable, and users would use for up to 15-20 minutes
Weakness: Back not straight enough. Sitting area not deep enough, and
much of leg not supported. If two users sitting on it, not a lot of room.
Comfort is not high
7. Cost 7.1 Commercial cost must be below AUD$1800
Testing Strategy: Expert Appraisal, Market Analysis

Strength: Manufacture cost per unit (including potential labour costs at
average Australian labour wage) is AUD$905. My competitor analysis of
high-end competitor products, including the few commercial products
featuring mycelium, has concluded this eco-chair could be sold for $1600
as a premium product
Weakness: This high price may mean it is not transferable to other
markets, such as private use
8. Safety 8.1 No sharp corners
8.2 Plants used must not increase risk of allergies
Testing Strategy: User testing

Strength: No sharp corners, with edges sanded. Plants not used and
mycelium doesn’t produce allergens
Weakness: Short chair means it is below line of eye sight for taller
percentiles, potentially making it a trip hazard
9. Manufacturing 9.1 Prototype able to be manufactured in school or local facilities
Testing Strategy: Design process

Strength: Silicone mats and mycelium cover produced in school. Base
wood pieces cut by local laser cutting business.
Weakness: COVID-19 Lockdown meant school facilities were
temporarily unavailable. Moving chair from school to home interrupted
mycelium growing process, causing uneven growth
35

Improvements to the solution While armrest has no support, mycelium

back built against wood
Change 1: armrest
Armrest made of
Two pieces mycelium, no
didn’t fully wood support
grow
together Armrest unstable
Also
Armrest too low armrest
Mycelium can and curved to be reduces
easily broken used comfortably seating
off as armrest area
Change: armrest to be removed as is impractical and unstable
Change 2: dimensions
Seat not deep enough
Dimensions of prototype Chair not wide enough to for comfortable use
comfortably sit two people
Uncomfortable
if two users are
strangers
Change: Seat lengthened to approx 1200mm, deepened to 300mm

Paint began to crack
Change 3: silicone mat varnish and paint after two days outside
Easily scratched
Medium blue-toned
grey paint clashes
with yellow wood
Wood colour
Change: Lighter yellow-toned grey paint and better varnish used
Change 4: silicone mat joining technique

Silicone mats Tacks Black tack
attached with scratch against
tacks to paint grey
Myclium
noticeable
and
Wood joinage: Doesn’t sit unattractive
mats blow off flat at
in wind edges
Change: Attach silicone mats with glue for better joinage
36

Change 5: Mycelium growing process

From beginning of mycelium
Mycelium covered in In controlled environment,
growing process
clingfilm to grow, temp & humidity mimic
conditions inside clingfilm Layers of mycelium
produces lots of waste
and mulch
Cling film
unnecessary,
reduces waste
Mycelium didn’t fully

grow into mulch
giving brown
appearance
Chair moved while growing
preventing even growth Change: Let mycelium grow longer, keep in warm, humid environment
Change 6: Etched numbers

Numbers etched into
Visible, wood pieces for
reduces identification
overall
aesthetic Time consuming to
appeal etch with laser cutter
Pieces different enough to not need
numbers to identify
Change: Remove numbers from pieces
Change 7: Seam in Mycelium cover Seam detracts from aesthetic appeal

Two slices of mycelium
laid on top of chair Join creates weak spot
One slice cut in half

used for backrest If mycelium grown in tubs length
of seat—no seam
Slices didn’t grow together,
creating obvious seam Mycelium slices will grow
together with longer growing
time
Change: Grow mycelium in large tubs, allow longer to grow
Change 8: backrest
Backrest too thick,
Backrest slopes back Backrest not
reduces depth of
too much— tall enough to
seat
uncomfortable fully support
Backrest curves back, reduces
down comfort
Mycelium
backrest supported Short backrest at
by wood base, can edge means Backrest only
be made taller mycelium doesn’t usable for one
fully grow on user
Change: armrest to be removed as is impractical and unstable
37

Evaluation of Individual Improvements on Whole Design (Criterion D)

Several of these planned improvements require changes when considering the product as a whole. To
support Change 2, (increasing the dimensions), thicker wood will be required to support the larger size.
Wood thickness is increased from 9mm to 12mm. Also, the amount of chair touching ground will need to
be increased for support.
Considering the changes in connection, some are linked. For example, Change 2 and 8 are linked, with
both requiring increase in dimensions. These changes can be considered as one change to sizes of vari-
ous elements. Changes 5 and 7 both relate to a change in growth process of mycelium, while Changes 3
and 4 relate to the silicone mat.
Overall, the changes can be summarised as:
- Size and form (Changes 1, 2, and 8)
- Mycelium (Changes 5, and 7)
- Small elements (Changes 3, 4, and 6)
Ordered above from most to least significant, these changes will be made in CAD models, allowing the
updated and improved product to be sent to manufacture and production.
Criterion E—Detailed development of a commercial product Design for disassembly

Proposed commercial product changes principles, reduces waste
Increases comfort over lifetime
Tall enough for Mycelium mould to for both users
comfort while be created to ensure
minimising consistent shape
Silicone mats All elements removable,
material
dimensions can be replaced as
increased to work needed
Seat back with larger chair
Seat back is 25cm straightened for Increases comfort
increased comfort Back curve
maintained, now small
Armrest removed, back on second seat Chair made deeper
with side shape
maintained for
aesthetic Wood thickness
increased to
12mm
Chair now
75cm tall
Silicone mats
thinner, so sit
better at edges Height to
seat
Silicone mats increased
attached with glue slightly
to improve aesthetic
Chair lengthened Thicker mycelium
‘Feet’ of chair to 120cm will allow more even
widened for stability Etched identification and controlled growth Increases comfort
numbers removed for upper
‘Feet’ also moved out Slightly more weight put percentiles, still
for more balanced Allows for increased on front to counteract accessible to lower
support comfort when two users tipping back percentiles
38

Detailed development of proposed commercial product changes
Change 1: Seat back Benefit Other implications for manu-

facturing
Seat back height increased Comfort Material increased slightly, hence
from 18cm to 25cm increased cost increases
Angle of seat back straightened by Weight increase, material
from 24° to 8° increasing thickness increased to 12mm
available to support
sitting
Seat back created for right seat space More mycelium and hessian
required to cover
Change 2: Benefit Other implications for manu-

Arm rest facturing
Armrest Sitting room increased, hence Less mycelium required,
removed comfort increased decreasing raw materials and
growth time cost
No longer unstable armrest, No armrest decreases comfort,
durability improved but overall, change improves
comfort
Change 3: Silicone mats Benefit Other implications for

manufacturing
Dimensions increased to 50cm x Maintain providing cover for Silicone required increased
29cm, as chair size increased mycelium and comfort for users slightly, small cost increase
Silicone thickness decreased from Mats sit smoother on mycelium, Thinner material means faster
4mm to 2mm increasing durability cutting
Silicone mats attached with glue, Mats attached more securely; Glue must be able to be removed;
not tacks reduces theft and hence material maintain modular design
wastage
Colour of silicone mats lightened Aesthetics of chair improved, More testing required to find exact
to match mycelium and wood increasing user acceptance right colour
Multiple coats of more protective Paint more and resistant to More testing required to find best
varnish used scratches and flaking, increasing varnish
durability
Silicone mat
Mat sits right colour closer
back to that of
against mycelium
seat back
Mat curves Mat curves

up at edge over edges
to cover to protect
mycelium mycelium
from user’s
legs
39

Prototype dimensions Change 4: Benefit Other implications for

Dimensions manufacturing
Chair length increased
Comfort Larger wood sheets required,
from 99cm to 120cm
increase, hence cost increase
Height to set increased particularly for Weight increase: material
95th percentile
Commercial product dimensions from 46cm to 51cm thickness increased to 12mm
as clearance to support
increased
Depth of chair increase Total amount of material
from 28cm to 32cm needed increased, cost
increase
Total heigh increased Larger scale manufacturing
from 64cm to 75cm required; 3-axis CNC
Change 5: Wood Benefit Other implications for

piece cutting manufacturing
Pieces to be cut Improved CNC machine must be
using 3-axis CNC efficiency for purchased
cutting pieces
Remove etched Increased Wood pieces can be identified
identification aesthetic appeal for assembly using part
numbers from drawings Etched identification number on
wood slices piece
Change 6: Mycelium Benefit Other implications for

Tub that growing process manufacturing
prototype Mycelium cover to be Increased Continuous mould for
mycelium initially grown in manufacturing mycelium to be created
grown in custom mould efficiency
(with lid)
Consistency in shape After mold transferred to
achieved chair to grow into hessian
Allow longer for Mycelium grows mat
57 x 40 x 30cm 50L Tub
mycelium to grow more even white
colour, increasing
Clingfilm used to maintain
aesthetic appeal
humidity while mycelium
growing on chair Keep the mycelium in Promote even Utilities cost increased to
warm, humid growing, ensure temperature and
controlled strengthening humidity control
environment when mycelium
growing Cling film not neces-
sary to control hu-
midity, reducing
waste
Change 7: Material Benefit Other implications for

manufacturing
Base slices material Bamboo’s sustainability Grey mat must be yellow-
change from Poplar and high durability toned, to go with yellow-
plywood to bamboo increases envrionmental toned bamboo Poplar Bamboo
benefit over Poplar
40

Manufacturing technique changes Wide tool required to Graphics

quickly reduce material generated
Mycelium mould creation
through
Tool 1: 20mm Small tool required to
Male mould created Fusion
Cutting diameter create smooth curves
using 5-axis CNC Manufacturing
Bull nose end
Simulation
Tool 2: 5mm
Cutting diameter
5-axis CNC ensures
smooth curve
Block weighs
approx.
1680kg Cut from 1500mm x Takes 120 hours to create shape
50mm x 350mm block
Aluminium costs approx Aluminium 6061 CNC Manufacturing costs:
AUD$3 per kilogram AUD$75 per hour
All excess material to Total CNC manufacturing

Overall aluminium cost=AUD$5040
create male mould costs: AUD$8500
High levels of Rendered male Male mould has dimensions

precision mould of ideal mycelium
unnecessary; cover (p44)
as natural
shape is
unique
Entire mould-creation
process to be
Only one aluminium outsourced
male mould to be Avoid costs of
Reduces material and created purchasing
manufacturing cost, and machinery
material waste
Natural curves
Female moulds made of of cover mean
Rendered female ABS thermoplastic
Mycelium cover grown Draft Angles
mould (top view)
to desired shape in unnecessary
female mould Cover grown from
layers of mycelium
and mulch in
mould
Hard
plastic Opening on
reverse side Low volume batch
production; only 10
As plastic unnatural Breathing holes to moulds to be
Mycelium can created
material mycelium facilitate mycelium
be popped from mould
will not grow into it growth drilled
after 2 weeks More moulds can be
produced if volume of
Mould kept in warm humid Mycelium then placed on
production increases
environment to ensure even growth chair to grow into hessian
41

Female mould (all measurements in millimetres)
Front view
Side view
Top view
3 axis CNC for chair base slices CNC improves precision

in manufacturing
CNC cheaper than
laser-cutting for large- 3-axis CNC allows organic
Wood pieces will be scale manufacturing curves to be achieved
manufactured using Wood base (No
CNC machine mycelium cover
or silicone mats)
Large laser-cutters
CNC has lower required for
operating costs manufacturing not
than laser cutters readily available
CNC readily Also, large laser cutters

available for very expensive
local production
in all markets 12mm diameter tool to be used
Allows slits in pieces to be

cut in one pass over
Laser cutting used for prototype Thicker 12mm wood
not appropriate for batch production easier to cut with
CNC than laser-cutter Reduces manufacturing time
42

Proposed commercial product—Full product
515
Units: millimieters
285
Scale 1:10
712
214
1079
1199
576
214
43

Proposed commercial product—individual parts
All measurements in Millimeters
Mycelium Cover
Front View
Side View
Even though armrest
removed, side curve
maintained for aesthetic
appeal
Chair slice Y-1

Side View
Front View
Material width same

for all chair slices
As in prototype, slices
inserted into each
other
No other joining
techniques required
Scale: 1:10
44

Chair slice Y-2 Chair slice Y-3

Side View Side View
Chair slice Y-5

Chair slice Y-4 Side View
Side View
Chair slice Y-7

Chair slice Y-6
Side View
Side View
Chair slice Y-8

Side View Chair slice Y-9
Side View
Scale: 1:10
45

Chair slice Y-10 Chair slice Z-1

Side View Front View
Chair slice Z-2

Front View
Chair slice Z-3

Front View
Chair slice Z-4

Front View
Scale: 1:20
46

Chair slice Z-5

Front View
Chair slice Z-6

Front View
Chair slice Z-7

Front View
Silicone Mat
Top View
Scale: 1:20
47

Third party manufacturing details (All costs in AUD)

20
18 19 21
1-17
Part Part Material Quan. Length Width Height Manufacturing Material cost Total
No. name (mm) (mm) (mm) method cost
1-17 Chair slice Bamboo 17 1200 750 12 3-axis CNC Approx. $15 $255
max max each
18 Mycelium Mycelium 1 1200 350 50 Growing in $25 per 500g $100
cover female mould bag, four
bags required
19 Mat Silicone 2 500 280 2 Laser cutting $15 per mat $30
20 Tacks Metal 20 12 2.3 - Outsourced $0.01 per $0.12

tack
21 Hessian Hessian 2 1200 700 - Outsourced $8 per metre $11.20
sheets
Total cost per unit: approx. $400
Other parts required for manufacture (Outsourced)
Part name Material Quan. Length Width Height Manufacturing Material Total cost
(mm) (mm) (mm) method cost
Mycelium Male Aluminium 1 1200 350 50 5-axis CNC $3 per Kg $13,540
mould 6061
Mycelium ABS 10 150 500 350 Thermoformed $80 per $1,200

Female mould mould mould
48

Criterion F—Making choices for commercial production

Justification of commercial production methods
Bamboo will be used for the interlocking wood pieces. Poplar Plywood was used for the prototype, further
research and discussion with furniture manufacturers has identified bamboo wood, which has a similar
colour, as a better option. As a fast growing wood, material production is efficient and sustainable,
meaning it is cheaper and more environmentally beneficial. Bamboo also has beneficial physical
properties, including high strength. With treatment, Bamboo can have lifespan of 50+ years, significantly
longer than Poplar's 20 years. Also, the material thickness has been increased from 9mm to 12mm. This
will increase material usage and cost slightly, but thicker wood is necessary to support the larger structure
of the commercial eco-chair.
As with the prototype, Mycelium is used for the chair cover. Benefits include absorbing carbon as it grows,
weather-resistance, and a lifespan of 15+ years. As mycelium grows into the hessian mats, these
elements can be removed and replaced if damages occurs. This design for disassembly increases the
chair's life span, which ultimately achieves higher cost efficiency.
Finally, the drainage mats will be made of 2mm Silicone Rubber sheets. Although made out of oils that
needed to be extracted from the ground using environmentally-harmful methods, the long 20-year life
cycle means the overall environmental impact across its life is reduced, with the cost efficiency also
improved.
Bamboo Mycelium Unpainted silicone
Justification of commercial production components

The hessian mat laid across the top of the seat, and the front of the seatback, is valuable, as it allows the
mycelium to be placed directly atop it, increasing efficiency of the manufacturing process. Als the
mycelium grows into the hessian, it secures the cover, while still being removable if needs to be replaced.
Steel tacks are beneficial as they securely attach the hessian to the wood base and require little assembly
time, but can be easily removed with a claw hammer.
The silicone mats, as mentioned above, allow for drainage incase of rain; the chair dries quicker. With
hardness increased with varnish, they also protect the mycelium from scratches, increasing its lifespan.
Painted silicone mats

Hessian mat on prototype Steel tacks
49

Justification of commercial production manufacturing techniques

CAD Programs: Programs like Adobe Illustrator and Fusion 360 are required
for efficient production, and allow changes to be easily made. The ability to
directly export to manufacturing increases efficiency, with designs drawn to
precise measurements allowing accuracy in manufacturing.
CNC: 3-Axis CNC, used for cutting the wood pieces, and 5-Axis CNC, used for
creating the male mycelium mould, are cost- and time-efficient. Appropriate for
batch-scale production, they're also widely available and extremely precise.
Creating the 17 base pieces takes 58 minutes, quicker than the 68 minutes with
laser cutting. Although the male mould takes a long 120 hours to cut, only one
is required.
Laser Cutting: This highly accurate manufacturing technique will be used for
cutting the silicone mats. Laser cutting the two silicone mats takes 18 minutes
each. As laser cutting is quick and requires little manual labour, it improves
manufacturing and cost efficiency, particularly for high volume production.
Growing: Mycelium is grown from a mushroom kit using alternating layers of
sugarcane mulch. For manufacturing, the mycelium can be grown in the female
ABS moulds, efficient for volume production and ensuring a consistent shape.
As the mycelium can be grown in all controlled indoor environments, this
technique is readily available. With total growth time taking 4-5 weeks, the
relatively fast growing process increases manufacturing efficiency.
Belt Sander: A belt sander can be used as a finishing technique to quickly
remove sharp edges of the wood pieces. The short time of 30 minutes for all
pieces increases manufacturing efficiency.
Spray Painting: As a finishing technique, using a spray can to paint and
varnish the silicone mats and wood pieces is efficient and produces a smooth,
even coat of high quality. The estimated time for all wood pieces is 15 minutes,
with two, one hour apart, coats required. Each silicone mat will require two
undercoats, two paint costs and two varnishes, each coat taking only 5 minutes. World—$24B
Scale and volume of commercial production AUS—$620M

As in Criteria A, the Victorian outdoor furniture market is AUD$150 million.
However, this market size is largely made up of purchasing furniture for VA—$150M
personal use, while the Target Audience of my product is Port Phillip Council.
Hence, while the full outdoor furniture market in Victoria cannot be reached, the
target audience can be expanded to other councils, using a batch production
strategy. Success achieved in each market will inform the launch of the next,
with an initial 21-66 units sold in the Port Phillip Market
Launch Period of No. of Potential No. Total available Total units (3 per
market testing before public of public market park)
next phase places spaces in
Low High Low High
launch urbanised
scenario scenario scenario scenario
regions (50%)
(10%) (30%)
1. Port Phillip 3-6 months 148 74 7 22 22 66
council
2. Victoria 12-18 months 682 341 34 102 102 306
3. NSW 10-12 months 870 435 44 131 132 393
4. Queensland 20-24 months 2100 1050 105 315 315 945
5. UK 5-6 years 27000 13500 1350 4050 4050 12150
50

Scale and volume of commercial production—continued

As in the table, after implementation at Acland Street, the market of the eco-chair would be expanded to
target other public places in the local council region of Port Phillip, before widening to the entire state of
Victoria. Other Australian states, New South Wales and Queensland, will be targeted, as they have similar
markets, and as two of the most urbanised states, combatting the UHI effect is more necessary However,
as there may be public parks in non-urbanised areas, it is assumed that only 50% of parks are affected
enough by UHI to justify this product, Of these 50%, between 10-30% are expected to purchase this eco-
chair, based on need and funding. However, those that do purchase an eco-chair will probably buy multi-
ple, as few public spaces have only one seat.
Pending success in Australian markets, the product will be launched in United Kingdom, as it has similar
market trends, and with 27,000 public parks, there is a large market. From there, it can be launched more
broadly internationally, targeting developed, environmentally conscious markets like Scandinavian coun-
tries.
Fixed costs (Source: Expert interviews, Variable costs (Source: Expert interviews,
secondary research) secondary research)
3-axis CNC machine: $90,000 Materials per Unit: $400
Male and female moulds: $15,000 Labour (Average labour wage $27/hour): $405
Machinery maintenance: $3,000 Shipping: $50
Other equipment: $3,000 Packaging: $50
Utilities: $2,000 Marketing and promotion: $15
Total fixed costs: AUD$113,000 Total variable costs: AUD$920
Following competitor analysis and expert appraisal, the unit selling price will be AUD$1600, with the chair
positioned as a premium eco-product.
At this price, the product will break even at 166 units sold. Therefore, it will likely break even in the Victori-
an market, allowing profit produced to be put into marketing, potentially increasing units sold.
The initial set-up costs are expensive, with the $90,000 CNC Machine vital for the manufacturing process,
as are the mycelium moulds. However, selling 166 units is potentially achievable in the first year of sales,
assuming an average of just over one order for 3 eco-chairs is put in every week.
Marketing will be used to boost sales, targeting local councils, specifically city planners, through direct
email communication.
If successful, this product could become part of a product family, with different sized chairs, stools and
benches created. Overall, through widespread sales and usage, this product, when implemented along-
side local government UHi reduction strategies, could aid the protection of the environment in even the
most urbanised cities.
Break even analysis for Eco-chair
Variable cost Fixed cost Revenue Total cost

$400,000
$300,000 Break even

point at 166
$200,000 units
$100,000
$0
0 50 100 150 200
Units
51

Design Technology HL Example 7 Out of 9 Work

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Design Technology HL Example 7 Out of 9 Work

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Design project 6 (HL): Outdoor seat

Criteria A - Analysis of Design Opportunity

Largest effect on most heavily urbanised

Almost everywhere, except parts of Africa,

Problem increases as global urbanisation

Figure 2: UHI effect in Melbourne Figure 3: Temperature increase in different areas of

Design technology teacher support material 1

Environment Analysis To road To tram

Findings from Acland Common seated activities

Customer Analysis User Analysis

Design technology teacher support material 2

Seating options at Acland Street Plaza (Source: Observation, primary research)

Aesthetics Simple Simple Simple Circle Simple

Safety No corners No corners No corners Corners round- No corners

Size Diameter— Diameter—1m Diameter—2m Width—70cm Length—>4m

More Ideal The market for outdoor furniture products is

Less environmentally friendly

Design technology teacher support material 3

Design technology teacher support material 4

Specification Rationale Testing method

4. Durability 4.1 The product A more durable product if more Materials

Design technology teacher support material 5

Key for annotations:

Small individual seats Seats at least two

Seats in middle are

Modern geometric Plants on back of Log flattened at top for

Modern geometric angular Plants on roof,

Nowhere to put plants Minimal structural supports, could fall

Plants on top stair and sides,

Design technology teacher support material 6

Develop and Refine Ideas

Iteration2: more circles

Leg arrangement Bench tips when

Design technology teacher support material 7

Developed idea 1—Greenery

Large greenery area

Functionality Environmental Size Safety Manufacturing

Developed idea 1—User feedback (St. Kilda residents)

5.1—Trendy and unique 5 6 5 6 5.5

5.2—Light colours 4 4 5 4 4.5

5.3—Use of circles 7 8 7 8 7.5

Developed idea 1—Required future iterations Developed idea 1—Decision

Design technology teacher support material 8

Less flexible in arrangements

Blends well with furniture Swing: fun and unique—

Developed Idea 2—Prototype testing

Decreases aesthetic appeal, ‘trunk’

If user swings Swing is too

Design technology teacher support material 9

Developed Idea 2—Greenery

Developed Idea 2—Assessing against design specification

Functionality Environmental Size Safety Manufacturing

Developed Idea 2—User feedback (St. Kilda residents

Aesthetics User 1 User 2 User 3 User 4 Average

5.1—Trendy and unique 4 5 5 6 5

5.2—Light colours 5 2 4 3 3.5

Developed Idea 2—Required future iterations Developed idea 2—Decision

• Increase stability of roof Will not be taken forward as:

Design technology teacher support material 10

Inspired by Lots of sharp corners

Could adapt to modular

Developed Idea 3—Prototype testing Seat curved for ergonomic