Alexander EttlDevelopment Engineer (Mechatronics)
Honeycomb Board Stool

Honeycomb Stool

Honeycomb board is cheap per area and remarkably stiff for its weight, but closed, it won't bend without the cells collapsing.

Open one facing and the cells lie exposed, each deforming on its own, so the rigid panel turns into a field of small hinges that can be laid around a radius. Clamped over a wooden form with the open face glued flat, the cells close again and from there the form decides the geometry, not the panel. No frame, no added structure, no second material, recyclable as a single stream.

Standing on it is the most honest test you can run on cardboard. Up to 80 kilos the stool showed no visible permanent deformation, and it failed above 100. More interesting than the 80 kilos is where it gave way first, and that's exactly what stayed open: did the cells buckle, did the facing peel, or did the joint come apart?

Two facings with cells between them
Open one facing and it bends
Clamp it to shape and glue it
80 kilos, no permanent deformation
Honeycomb Stool
Two facings with cells between them

Open one facing and it bends

Clamp it to shape and glue it

80 kilos, no permanent deformation

At a glance

Context
Semester project with a packaging manufacturer
Period
Summer 2023 · 3 months, ~150 h
Role
Team of three with Helena Dinkhoff and Nicolas Schmeding. Mine: the manufacturing principle. Supervised by Prof. Kostas Medugorac and Hannah Steinmetz.
Disciplines
Industrial design and Mechanical
Evidence
a built prototype, measured data, manufacturing process and documented iterations

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