Crafting Creativity with Timberflex: A Student Project Spotlight

At Kerfkore, we take immense pride in supporting young designers as they push the boundaries of creativity and innovation. One such talented individual is Rudy Sullivan, a Furniture Design and Manufacturing major at the Minneapolis College of Art & Design (MCAD). Rudy recently completed an exciting project using our Timberflex panels for his final assignment in MCAD’s Textile and Surface course. Titled “Unconventional Covering,” the assignment required students to upholster, cover, or skin a piece of furniture with an uncommon material. Rudy’s resulting piece, a chair whimsically named “Craft Mac & Chair,” showcases the versatility and potential of Timberflex in furniture design.

Unconventional Origins

Rudy’s journey to becoming a furniture designer is as unique as his final project. Initially, Rudy pursued a business degree at Marist College in New York. However, during the COVID-19 pandemic, he rediscovered his passion for design and fabrication, leading him to transfer to MCAD. The promise of hands-on experiences like sketching, prototyping, and fabricating drew Rudy into the world of furniture design.

“To be a good designer, one should be informed about consumer trends, supply chains, and a general sense of what is going on in your target market including the housing market and what kinds of properties consumers are buying,” says Rudy. His background in business continues to inform his design approach, blending creativity with a keen understanding of what consumers want and how businesses function. 

The Project: Craft Mac & Chair

The Unconventional Covering project challenged Rudy to think outside the box — one of Rudy’s strengths as a designer. 

“During my three years at MCAD I have tried to experiment with as many tools, techniques, and materials as I can,” says Rudy. “Design school is the perfect place to experiment and to make mistakes. As a creative, mistakes can eventually produce excellent results. I try to always be moving forward and not become complacent with a certain material or technique.”

Rudy’s process began with some simple noodling around with Timberflex. “I am heavily influenced by material,” explains Rudy. “When I walk into the lumber or metal yard, ideas often come rushing to my mind.”

After testing the bendability of Timberflex, Rudy began modeling his design in Fusion 360, a computer-aided design (CAD) tool, and then creating renders in Keyshot, a 3D rendering software. 

After rendering his mac and cheese-inspired design, Rudy began fabricating. Using a track saw, he cut the Timberflex into the necessary dimensions. He then crafted sloped armrests with a handheld router and created slots for the seat and bottom support made from MDF. 

After assembling these components, Rudy veneered the visible kerfs, edge-banded the Timberflex and MDF, and applied a coat of Benjamin Moore’s Scuff-X paint for durability. The final touch was an unconventional orange plastic covering, folded and sewn together, and attached with a pneumatic upholstery stapler.

The completed piece is titled Craft Mac & Chair — for reasons that may appear obvious to any hungry readers. 

“The title refers to the orange color, the fun and extravagant nature of this piece, and the craft and skill it took to make,” explains Rudy. “This project is more sculptural than my previous design work and maybe goes against some of my philosophies but I love this chair and its silly and absurd nature. It is a great success.”

Why Timberflex? 

“As the Unconventional Covering project began, I had several designs that had curved features,” says Rudy. “I also wanted to use the Timberflex as I was eager to understand its abilities.”

The use of Timberflex also significantly streamlined Rudy’s fabrication process.

“The Timberflex saved me an amazing amount of fabrication time,” Rudy notes. “If not for Kerfkore’s amazing support, I would have to buy particle board, laminate it with some material, and then cut all the kerfs myself. Having the Timberflex ready to use straight off the pallet was extremely convenient. This also made it possible to think more about the covering and other parts of the fabrication.” 

The biggest challenge Rudy faced was achieving the chair’s semi-circular shape. Timberflex’s flexibility made this task manageable, allowing Rudy to experiment with larger radii and achieve the desired form with ease. The material’s pre-kerfed nature also facilitated the construction, making it possible for Rudy to concentrate on the intricate details of his design.

“The material donation allowed me to experiment in a less stressed manner. I felt I could try things, make mistakes, and take more risks,” recalls Rudy.

Rudy’s Plans for the Future

The leftover Timberflex will not go to waste. Rudy plans to incorporate it into future projects, including his senior project, where he will be required to design and build several pieces of furniture. This experience has profoundly influenced Rudy’s aspirations as a furniture designer. He sees great potential in using commercial building materials like Timberflex to create cost-effective, well-made, and interesting furniture.

“I have always been inspired and interested in commercial building materials,” says Rudy. “I think they can make furniture that is more cost-effective in terms of production, providing a lower cost to the consumer. Consumers increasingly want well-made, interesting objects and furniture.” 

Ensuring More Inspired and Cheesy Designs With Timberflex

Rudy Sullivan’s “Craft Mac & Chair” is a testament to the power of innovation and the possibilities that engineered kerf products like Timberflex offer to designers. At Kerfkore, we are thrilled to have been a part of Rudy’s creative journey and look forward to seeing his future projects. His work not only highlights the versatility of our products but also inspires other designers to explore new materials and push the boundaries of conventional design.

You can contact Rudy at RudySullivanStudio@gmail.com and check out more of his work on his Instagram account, @RudySullivanStudio, and at his portfolio here.

For more information on how Timberflex and other Kerfkore products can enhance your designs, check out our product catalog or request a sample yourself! Stay tuned for more project spotlights and innovative projects showcasing the endless possibilities with Kerfkore.