Reverse engineering

the staves: the parts and assembly of coopered barrels are disassembled, then re-assembled using the hypotheses imagined to produce free-form complexly curved surfaces
A

Jig

is designed which would be capable of cutting the digitally-designed unique profile and bevel cuts, using only a hand router

Test cuts

The rails are positioned according to precise measurements taken from a digital model; the staves' profiles and variable bevels are cut simultaneously using a hand router

Test assembly

An early test in MDF proved that the staves could provide shape for each other, but that the profile cuts mattered much more for the global shape than did the bevels

Paper tests

The geometries discovered through initial testing are reduced in scale to paper strips, the profiles of which can be used to explore self-forming stave possibilities
Several

design choices

are generated using the new paradigm
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