The self impose 2x2’ limitation isn’t really mine, it’s just that plywood is generally 4x8’ and I don’t want to throw a bunch of wood away, or have a ton of scrap that I “may use someday”. The general cutting area of the XXL is around 31x31" without using the overhang, if I cut chairs out of 31x31" I would have a ton of wasted wood (I’m using 3/4" maple plywood, not the cheapest). I’m also using VCarve Desktop which has a 25x25" limit unless I use tiling, and I want these to be fast to cut with minimal bit and material changes. Right now I can cut the whole thing using one 1/4" single flute straight router bit and the only material changes are actually loading a whole new sheet/chair. I move from there to the band saw to cut the tabs off, then an oscillating spindle sander and 1" belt sander to remove any junk left over. I don’t want to do a whole bunch of finishing on these other than knocking off edges and a spray of clear poly. This is also why I don’t want to use any fasteners or glue if possible, just a rubber mallet, 5 minutes, and done. I’m not quite there, but hopefully when I get the final design done it will be as easy as it sounds, the first prototype had some fit issues and still needed some screws. Looking now at glue less joints that can be cut on the CNC, but that aren’t removable once pounded in place.
The design is not totally my own, although I’d love to take credit for the idea, if you do a Google search for “flat pack stool” you’ll find a bunch of different designs, some very close to mine and some very different, but the idea is the same. Maximum material usage, easy to assemble, “flat pack” for easy shipment,…I actually think this is an Ikea brainchild.
Thanks for looking,