Terra Table

Product Overview and Project Motive

This organic coffee table project was born from an exploration of generative design using MidJourney’s AI-based image generation tool. Our initial goal was to experiment with unique accent table designs, and through this process, we discovered a range of creative and unconventional forms that captured our interest. The designs we generated were not only aesthetically compelling but also well-suited for production through advanced 3D printing technologies.

As we refined our vision, we focused on selecting forms that showcased the unique capabilities of additive manufacturing. Traditional manufacturing methods like 5-axis CNC machining, while capable of producing complex shapes, are often prohibitively expensive and limited in their feasibility for highly organic forms. By embracing 3D printing, we aimed to break free from these constraints and highlight the potential of additive manufacturing for creating intricate, sculptural furniture pieces.

Design Concept

We focused on accent table designs with sculptural aesthetics, generating a wide variety of organic shapes. Through this process, we shortlisted concepts that balanced visual intrigue and manufacturability, keeping in mind the unique capabilities of additive manufacturing.

The final product is an elegant, organic coffee table featuring two fluid, trunk-like support structures topped with a round, tinted black glass surface. This combination of flowing, nature-inspired forms and refined materials results in a striking statement piece that balances artistry with functionality. This project stands as a testament to the power of digital design tools and advanced manufacturing techniques to bring visionary concepts to life in ways that traditional methods cannot achieve.

DfAM (Design for Additive Manufacturing)

This design leverages Design for Additive Manufacturing (DfAM) by embracing forms that would be incredibly difficult or prohibitively expensive to produce using traditional manufacturing methods. The flowing, interconnected structures are optimized for 3D printing, allowing for the creation of complex geometries without the need for assembly from multiple parts. This reduces material waste, minimizes production time, and maintains structural integrity in a single print.

One key DfAM strategy employed was optimizing the design to print without support structures. By carefully orienting the parts and refining surface angles, we eliminated the need for additional support material, reducing material waste and post-processing effort. This approach ensured a clean finish while maintaining the integrity of the organic shape.

Furthermore, the design takes full advantage of additive manufacturing’s ability to produce lightweight yet sturdy forms. The table achieves a perfect balance of strength and efficiency by optimizing wall thickness and internal structures. This approach pushes the boundaries of furniture design and underscores the transformative potential of advanced manufacturing techniques.

3D Printing Manufacturing

The organic coffee table was manufactured using an Anycubic Chiron FDM 3D printer, known for its large build volume and precision. The print process lasted five days and required more than 3kg of high-quality PLA material. Thanks to the optimized design for additive manufacturing (DfAM), the entire base structure was printed without needing support materials, reducing waste and post-processing time while maintaining a clean and intricate form.

For the tabletop, a round, tinted black glass surface was custom-cut to a diameter of 420mm with a thickness of 13mm. This refined glass top complements the sculptural base, creating a sophisticated contrast between the base's organic form and the glass's sleek finish.

Post Processing and Assembly

Post-processing for the 3D-printed table base involved light sandingto address stringing issues. Stringing occurs when small strands of melted filament "ooze" out of the nozzle during movement between print points, leaving unwanted "strings" on the printed object. This is typically due to improper retraction settings or a nozzle temperature that is too high, causing excessive filament flow. This issue arose in this model because of the relatively large distance separating the two trunk-like structures. After light sanding and cleaning, the assembly phase followed. The glass top was attached to the table base using a UV bonding agent/glue, perfect for maintaining a clean, seamless look. UV adhesives guarantee a transparent bond thanks to their refractive index of 1.5, similar to glass.