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Exo Layer Stool

A 3D printable and collapsable stool utilizing NASA’s Space Fabric design. Shortlisted design for the IDSA x Makelab Layer Competition 2024.

Date
In Progress
Role
Lead Product Design
CAD Modeling
Rendering
Design for Manufacturing
Project Type
Industrial Design
User Experience
Manufacturing
Featured
Reuters
Redesigning The Spoon For Space Dining
[Aug 2021]
Overview

The Exo Stool is a flat-pack seating solution inspired by the tripod frames of traditional tepees and NASA’s space fabric. Designed for the Layer Logic Design Competition, it merges historical and futuristic elements to create a stool that is compact, tool-free, and ergonomically supportive. Its innovative chainmail-like seat mimics the flexibility of fabric, adapting to the user’s body for comfort while fitting seamlessly into both indoor and outdoor settings.

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The Challenge

Design a flat-pack stool using only PLA, optimized for 3D printing with a maximum 30% infill. The stool must be tool-free to assemble, support 180 lbs, fit within a 14 x 14 x 14-inch build volume per part, and not exceed 18 inches in height. The design also needed to minimize material waste, ensure ergonomic comfort, and balance compact storage with sturdy functionality.

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Approach

We combined inspiration from timeless structures and innovative materials to create a stool that balances aesthetics and functionality. By employing systems thinking, we designed components with minimal material waste, easy assembly, and maximum strength. The adaptable seat and modular design allow the Exo Stool to be both compact and versatile, making it ideal for small spaces and adventurous settings alike.

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Concept Overview

The Exo Stool draws inspiration from NASA’s space fabric, featuring a chainmail-like seat that mimics the flexibility and adaptability of woven materials. Paired with a tripod-inspired frame, it combines innovative materials with tool-free assembly and compact flat-pack storage for versatile, ergonomic seating.

Tool Free Assembly

The Exo Stool features an intuitive, tool-free assembly system. Its tapered connectors allow the seat to slide effortlessly onto the legs, while a central brace secures the structure. Hidden curved dovetail joints in the legs add stability when assembled and easily disassemble for compact storage.

IDC 2024 - Austin, TX

The Exo Stool features an intuitive, tool-free assembly system. Its tapered connectors allow the seat to slide effortlessly onto the legs, while a central brace secures the structure. Hidden curved dovetail joints in the legs add stability when assembled and easily disassemble for compact storage.

Process

Understanding the Space Paradigm

The current design process of a new mission is lacking consideration for higher human needs. The process focuses on retrofitting basic human needs in the machine in the stages of Implementation rather than considering all the human needs in the earlier stages of the process

Industry insights

Given the highly specialised nature of the space industry, it was important to engage with experts. I conducted semi-structured interviews with space engineers and space food researchers to collect insights and validate my research.

Project Methodology

I iterated the proposed methodology by using the development of the products as testing grounds to validate it and collect insights for improvements.

Testing through prototyping

I used a mix of prototyping probes and co-design workshops to test my hypothesis for an alternative methodology of creating human artefacts for space.

Testing through co-design workshops

Even though I was working in a vacuum with no real constraints and requirements, the findings helped me develop an iterative process and refine my methodology.

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