News from PilgrimWaters Studio!
We have created a tray stand for our popular oversized wooden trays. In response to customers who wanted to use the tray as a small table. Over the past few weeks we have been designing, prototyping and testing.
For this project our goal was to create a compact, folding stand able to function at different heights. The first design worked fine on screen/paper with a rotating hinge and material strapping.
However, as you can see below, version 1 was rather flexible and looked a bit skinny. The straps also prevented the tray stand from folding away flat which was a key feature we wanted to maintain. So back to the drawing board.
The rotating hinge was also a slight design flaw because it wasn't robust and added another expense to the finished product. Simplicity was key and we wanted more functionality than just a single height. Ideas from small furniture and laser cut ply suggested that components might be the way to go. So a two part slide together design came to mind.
This was a design improvement we liked so it was time to make another prototype version 2. Now we were getting somewhere! Next was the material usage which was a bit high, i.e., the width of the ply could be skinned down to save in weight height and material usage. Only when version 2 was finish was it clear that there were mechanical and structural weaknesses on one side. This was solved by adding an additional cross brace.
Version 4 and 5 were about the same. Two heights would be good and perhaps it could fit inside the tray as a design functionality? So here's the tray stand fitting in the tray.
Well, because it could fit inside the tray then it could also lay horizontally at the second height. Bingo! We have arrived at prototype version 5.
Of course it works the other way up as well - done. The prototype was finished which brings us to the top image of the finished prototype.
Here's the final version upright. Each surface is glued and connected using hidden dowel-pins and biscuit joints.
Finally, here's a small video on how to put the tray stand together - enjoy!
-Keith and Susy