Our competition submission for the 2013 Design By Nature exposition is a collection of four concrete composite cubes (measuring 2.5 cubic feet each) that have industrial volumes ‘subtracted’ from 3 or more of their 6 surfaces. The durable cubes can be oriented together or separately in a variety of configurations. Each cube will contain a recycled foam core, which reduces their weight considerably compared to solid concrete masses of similar size. This makes the pieces suitable for both indoor and outdoor uses to include: low + high seating, side tables, coffee tables and sculpture.

OUR INTEREST

Industrial, cast metal pump casings often start out in the wood shop.  Millworkers + machine operators carve solid, laminated wood blocks to create ‘patterns’ that are used to make sand-moulds. The sand-moulds are then used for casting.  It is common for companies to make one-off castings, which means that the patterns go to waste after their first use.

Our design team was exposed to an overwhelming number of decommissioned patterns this year. They are beautifully crafted relics of Canadian manufacturing.  We approached Tim Sheppard, a local pattern maker with our idea for a Design By Nature proposal. He graciously agreed to donate a retired pattern component called a ‘core box’ that meets our size specifications perfectly.

 OUR PROCESS ( See corresponding diagrams below)

A - Section the ‘core box’ into quarters and form the sides of each quarter using off- cut lumber

B- Suspend recycled pieces of dense foam insulation inside the formed quarters + pour fiber-based ECC (Engineered Cementitious Composite) into the core boxes

C- Extract the new cast volumes, polish and seal them. Compose them based on desired use.

SUSTAINABILITY

Our process uses exclusively recycled material except for the outer cementitious skin + sealer. Virgin material use will be limited to 20% or less in this project.

In April we posted Chair 1.2 built in solid walnut. Version 1.3 is a simplified prototype – made up of offcut birch, maple and walnut. We eliminated the side profiles and steel tenons to give the chair a more contemporary look and feel. The structure is now fully exposed and clearly defined.

Dimensions are: 34″ H back / 19″ H seat x 20″ D x 17″ W.

For information about available wood species, customization, pricing, or to place an order, please email us at info@stacklab.ca

* Chairs 1 – 1.3 are collaborations with local Toronto designer Arash Sadr

The Square Cut Burl is a new addition to our portfolio. The orthogonal table top is made from an irregularly shaped historic burl and clear, cast resin. The images below document some of the initial process.

Please email us at info@stacklab.ca for information about pricing or to place an order.

Desk 2 is a 10′ x 38″ x 3″ historic old redwood burl paired with our sand-cast aluminum ‘Wishbone’ legs.

The top is finished with natural oil and wax and the legs are hard anodized clear.  Both Wishbone castings are installed flush with the underside of the slab using countersunk, stainless-steel machine screws.

Please email us at info@stacklab.ca for information about our work, pricing, or to place an order.

In March, we posted a prototype for a chair we are developing with Toronto-based designer Arash Sadr. Since then, we have made a few adjustments to the design. The updated version is shown below in solid, Canadian black walnut and cold-rolled steel.

Dimensions are: 34″ H back / 19″ H seat x 20″ D x 19″ W.

Wood Finish: hand rubbed polymerized tung oil and wax

Steel Finish: clear matte powder coat

For information about customization, pricing, or to place an order, please email us at info@stacklab.ca

In October 2012, we posted a schematic proposal for our first private table commission in New York. The project is now complete.  Our signature ‘wishbone’ legs are shown below in a polished bronze finish and are paired with a book-matched black walnut tabletop with corresponding bronze ‘stitches’.

For information about our work, pricing, or to place an order, please email us at info@stacklab.ca

Images are provided by Toronto photographer: Alan Hindle

We recently posted about our new signature cast table legs called the ‘Wishbone’. We now have three finishes available on a made-to-order basis out of our studio on Eastern Avenue in Toronto. The images below show two aluminum finishes: hard anodized (1-2); and polished (3-5). The third finish we are offering is cast bronze. Stay tuned this week for some spectacular images of the bronze that we are using in our first american table commission.

For more information about pricing, or to place an order, please email us at info@stacklab.ca

Our first chair is in the making. This design is a commissioned collaboration between our studio and local Toronto designer Arash Sadr. We are very thankful to our client, Afrothite who gave us the opportunity to develop this concept. She will own the first limited-series constructed from solid walnut and clear coated, cold-rolled steel. The images below of our preliminary birch prototype show the general construction and proportions of the chair – however, they do not yet include the finer details that we are most enthusiastic about – such as a curvilinear seat profile, a series of rectangular wood dowel inlays and the introduction of a 2-3mm technical  felt seat and back. So, stay tuned for the next version.

We intend to experiment with slight variations in the existing design, materials and finish on a per project basis. Please email us at info@stacklab.ca for information about our custom design + build services or to place an order.

Our friends Estelle and Sean did a terrific job of designing and refurbishing their new place in the Dundas West area of Toronto. Proof again that with time and patience, homeowners can do something special with a realistic budget. We collaborated with the pair on a few a-la-cart pieces that give recognizable brands a bit of a personal touch.

Image 1:   Historic redwood burl coffee table top paired with classic hair pin legs from Lunar Lounge Design.

Images 2 + 3:  Solid black walnut island surface fastened to a standard base from the IKEA kitchen line.

Image 4:  Solid black walnut shelves supported by four of our custom stainless steel side-mount bracket sets.

Image 5:  Reclaimed, white-oak bench seat atop two signature low-table legs from the Eames Collection.

Photos courtesy Module Media

For information about our custom design and build services, pricing, or to place an order, please email us at info@stacklab.ca

Will and Porsha are true cocktail connoisseurs. We designed this 7′-10″ shelf as an alternative to a traditional liquor cabinet for their new home. Rather than hide their impressive collection of hard-to-find bottles behind doors, we elected to showcase them in the open. The large bottles sit on the top at an easy height of 56″. The smaller bottles (mostly bitters) sit in an inset 10″ cavity. A low-profile, 1/4″ steel rail borders the shelf surfaces to prevent bottles from falling without interrupting the view.

We collaborated with the talented woodworkers at P & P Custom Living on the construction of the ’Top Shelf.’ It is built from solid black walnut with internal hollow sections to reduce weight. The corners are mitred and are supported by a plywood skeleton. The assembly hangs from the existing wall and does not require any internal blocking.

The images below document the project from start to finish.

For information about our custom design services, pricing, or to place an order, please email us at info@stacklab.ca

In April of last year we posted about a table leg prototype that we were developing called the ‘wishbone.’ Originally, the leg was intended for smaller tables, however, due to demand, we have redesigned the leg to bear greater loads. Currently we are in the process of making the first three pairs in a limited series for sale out of our studio on Eastern Avenue in Toronto. We are offering this leg design in three materials: polished solid cast aluminum, polished solid cast bronze, and hard anodized cast aluminum.

Prior to making the first casting (shown below in rough aluminum), we performed a number of stress tests to optimize the leg shape and volume for heavier loads. The diagrams below show a series of exaggerated stress conditions that helped us finalize the design:

1) Force applied from the side ( simulating a heavy nudge in direction x); 2) Force applied from the side ( simulating a heavy nudge in direction y); 3) Force applied from a corner ( simulating a person sitting / leaning XYZ); d) Force applied from above Z (simulating a person dancing on the table)

Stay tuned for further news as we go through the last stages of production. For information about pricing or to place an order, please email us at info@stacklab.ca

Our good friend Isabelle, owner of the local high-end jewelry/accessories store Rue Pigalle, has encouraged us to develop a series of necklace displays. Over the next while, we are going test these products by making a limited series of the schematic representations below. These busts will be made using fully integrated digital design and fabrication techniques. After experimenting with a number of materials we have chosen a massive timber product- similar to CLT – however, made up entirely of laminated Canadian maple. The finish will be a VOC free, hand rubbed, polymerized tung oil.

For information about pricing or to place an order, please email us at info@stacklab.ca

Toronto architect Rochelle Moncarz recently commissioned us to make a big, blue ribbon leg for a butcher block island in a house she designed. The leg was fun to make as always, but it was especially good to meet Rochelle and see her work. She was able to transform a typical, terraced-style, Toronto home interior without breaking the bank. Her material choices, finishes and plan alterations work well together to create a space that is easy to use, comfortable and stylish. Not an easy feat with a small, downtown floor plate.  If you need an architect, we suggest Rochelle. Below you can see a photo of the kitchen, courtesy of photographer: Scott Norsworthy.

For information about our custom fabrication services, please email us at info@stacklab.ca

In October and November of this year we posted about Richmond Station. We are happy to announce that the restaurant is now open and thriving. Congratulations to Ryan Donovan and Carl Heinrich: the butcher and chef team behind this great new business. Below, there are some recent photographs of the completed 80-seat space. Our intent was to provide a utilitarian environment for Ryan, Carl and their support staff. We emphasized simple, honest materials, easy circulation and modulated storage to make the space work. We are particularly proud of the use of architectural grade Cross Laminated Timber (CLT) for the communal table tops in the standing area, and in the private dining pantry.  Richmond Station is among the first spaces in North America to use CLT in a furniture application. This incredible product will play a prominent role in sustainable construction in Canada, and we are thrilled that Ryan and Carl supported us in our efforts to feature it in this project.

For more information about our interior design services, or about CLT, please email us at info@stacklab.ca

Last week we posted about the 11′-1″ American Elm table that we made for the Union Lofts sales centre. The space is now open and we are proud to show off a few preliminary shots of our piece in situ. There will be more photos coming following a group shoot with the interior designer and our collaborator: Studio Kantelberg.

Union Lofts, the latest from the Windmill Development Group is opening their sales centre this coming Saturday, November 17th, and we will be there. Union will be a church-turned-living space located at 243 Perth avenue in the Junction Triangle. While construction on the lofts hasn’t begun yet, part of the church interior has been beautifully transformed by Studio Kantelberg. We had the honour of collaborating with Andrea Kantelberg on the design of an 11′-1″ American Elm communal table that will serve as a feature of the space. This table is especially important to us because of its origin.

The top: comes from Wychwood Park. A very good friend of ours named Robert Green slabbed the fallen Elm on site for us about two years ago. Once we secured the commission, we called Rob up who now works with a new crew of talented woodworkers P & P Custom Living to see if he would work with us on the project. He agreed. It is very nice to be working with Rob again, and to see him involved in bringing the piece to completion

The bow tie joints: are CNC milled from a mahogany stair tread that we reclaimed from a farm house in Caledon. They were milled, yes, but they were installed the old fashioned way.

The legs: are bright bright purple. A big thanks to Ben Lowry ( on the development side) and to Andrea for supporting the idea of a leg modelled after an old set of colorful saw horses we use in our shop. We’ve wanted to do this for a long time.

See below for some images of the making of the table – including one shot of the original elm tree before it fell. Stay tuned for more of the completed piece, and, please email us at info@stacklab.ca for information about our design + build services.

On September 18th we posted our schematic proposal for the BLOOM Sustainability Leadership Award commission. Since then, we have completed the final award. This was a collaborative effort between ourselves, the Bloom Centre for Sustainability and Marc Littlejohn- a very talented acrylic fabricator in Toronto. Below, you can see the finished artifact along with a few process shots and a video of us CNC milling the heartwood dowel- the small piece of reclaimed white oak that we used to generate the pattern on the front and rear acrylic surfaces. The dowel is machined with a high level of precision so that it can be pressure fit into the acrylic cavity without any adhesives or aides.

The Sustainability Applied 2012 event takes place this Wednesday, October 17 at the Metro Convention Centre in Toronto. We wish the three finalists: BASF, Loyalty One + PepsiCo Canada the very best of luck!

Please email us at info@stacklab.ca for information about our custom design + build services

We collaborated with the very talented Jonathan Enns (ennsdesign, Solid Operations) on the conceptual design of Richmond Station. In the very early stages of the project, Jon introduced us to an innovative product called Cross Laminate Timber (or Massive Timber) that he has researched extensively.

In 2009 Jonathan was selected  by Princeton University as the recipient of the Butler Travelling Fellowship for which he travelled to Austria, Scotland and Finland to study CLT. In particular, his research involved a two fold search: 1: For ways in which the use of large quantities of sustainably grown timber could be used in lifecycle carbon calculations (and be a competitive ‘green’ tactic in design), and 2: How CLT in Europe is being mobilized to challenge conventional construction in these regions, particularly at spans and scales previously reserved only for steel and concrete.

Jon explains that:

Research in this area is becoming more and more common in Canada, as both the process and production of CLT holds huge potential for the building industry and the production of architectural form.

At the small scale, CLT holds benefits as a replacement for Old Growth or reclaimed timber, being available at comparable (and likely larger) scale, while being composed of what has been seen typically as low value lumber.  Being both cheaper and dimensionally stable, certain applications at the small scale would find benefits in CLT, although clearly it will never be a full replacement: Old growth has characteristics (both aesthetic and performative) unique to itself. What it would allow for however, is an increased preservation through a more strategic deployment of these characteristics. Thus for applications in which the aesthetics of CLT are sufficient, it is a worthy and interesting replacement.

This said, the unique properties and advantages of CLT clearly become obvious at the large scale. Construction with CLT is fast, light, and quiet, it can be achieved with simple tools (read: no hammer drill, no burnt out elbows), and is in many cases financially superior. Relying on a certain element of ‘prefabrication’ the process that full building in CLT imposes is in itself a sort of revolution for the building industry (especially in Canada), but is one that holds extremely exciting potentials both in terms of the environment, and –as with any new technology/process–in the production of novel architectural form.

Below, we have attached images of a small sample of CLT that Jon brought back with him from his travels. This sample belongs to KLH – a leading manufacturer of CLT based out of Austria. We also have attached images of two of the communal tables that we made with Jon for Richmond Station.

Stay tuned for images of the completed restaurant due to open in early October, and for future projects involving CLT.

Please email us at info@stacklab.ca for more information about this product.

Walnut 2 is a proposal for a private commission in New York City.

The  10′-1″ table top will be made from two mirrored walnut slabs cut from the same fallen tree. They will be flattened to a 1 3/4″ thickness and bookmatched.  The legs are a slightly modified version of our Wishbone Leg prototype. For this project, we will be casting the leg in bronze and increasing it’s overall size to accommodate the larger table top.

Please email us at info@stacklab.ca for information about our custom design + build services

The summer was a very exciting time for us because we had the chance to work with three very talented people on a great project called Richmond Station. Richmond Station is the restaurant that Carl Heinrich (Canada’s Top Chef 2012) is opening this October in downtown Toronto with his longtime friend and business partner Ryan Donovan. The design of the space is a collaboration between ourselves, Jonathan Enns (ennsdesign, Solid Operations), Ryan and Carl. It will be a simple + utilitarian restaurant: built so that two cooks at the top of their game can do what they do best. Below, you can see a combination of progress photos, schematic design concepts and working drawings for the project. Stay tuned for images of the completed space, and for information about some of the specifics that we like the most.

Please email us at info@stacklab.ca for information about our interior design services.

The Bloom Centre for Sustainability  is a unique organization who “brings together public and private sector interests to drive change, and implement sustainability initiatives that deliver economic, environmental and social benefit.”  We like Bloom because they view sustainability differently than the majority of their peers. They approach their work through the pragmatic lense of “best use, best return.”  We see them as believable agents of change and we are honoured that they commissioned us to design and build their new Sustainability Leadership Award. Our final schematic proposal (first 2 images) is shown below with a sample graphic of a digitized growth field (3rd image). Each award will have a portion of its own unique ‘field’ etched on two of its surfaces. Each field is achieved by photographing a small off-cut piece of heartwood; translating the grain pattern into pixels; and then ‘growing’ those pixels with a parametric script.  This design represents the integration of sustainability as a process of optimization, growth and change. It shows how the simplest idea can be totally re-imagined and still maintain its core values and intent. Please stay tuned over the next few weeks as we discuss the project design in more detail and prep for fabrication.

Please email us at info@stacklab.ca for information about our custom design + build services

Rue Pigalle is one of our favourite retail stores in Toronto. Their brand new Queen St location is full of innovative jewelry and accessories that are handcrafted in Europe. Go check out the clever ways that  these artists and artisans use material. We were especially impressed by a fantastic series of necklaces made of cast rubber!

Isabelle, the store owner graciously commissioned us to make her 3  28″ x 28″ display tables shown below.  We made these pieces from local reclaimed wormy beech and tubular steel. The top of the legs sit flush in routed pockets in the underside of the top. The mid-leg passes through the lower shelf which is supported in place with 4 set screws. The feet have a built-in levelling adjuster. Thanks to Isabelle for the support and to Rue Pigalle for the inspiring products.

Please email us at info@stacklab.ca for information about our custom design + build services

Benji’s Walnut Table is a recent commission we built for a private client in downtown Toronto. The reclaimed black walnut slab top is 2″ thick and runs 7′ -7″ in length. Our tapered ribbon legs are welded, pickled and oiled, hot-rolled steel. We finished the table with a VOC free hardwax oil and the legs in a clear gloss powder coat. A very big thanks to Benji for his support!

Please email us at info@stacklab.ca for information about our custom design + build services

This is a continuation of last week‘s post – documenting our process of modelling and fabricating a prototype cast aluminum leg for our retail portfolio. We are now one step away from having a finished custom leg: These casts were hardened using a heat treatment and then prepared for finishing by grinding away the draft (the excess aluminum) and then sandblasting.  Stay tuned for updates on this project and please feel free to contact us at info@stacklab.ca with questions or comments.

Currently, we are in the process of prototyping a cast aluminum leg for our retail portfolio. The wishbone shape shown below starts with an inset crotch arch and then curves and tapers downwards in two directions. This week, with the help of our collaborator Styropatterns Inc., we will CNC mill a positive and negative mold pattern for each leg. Once we have the patterns milled, we will take them to a foundry where the metal workers will cast the shape for us. Stay tuned for updates on this project and please feel free to contact us at info@stacklab.ca with questions or comments.

*The schematic diagrams below are representational

We have moved into a fantastic new studio at 28 Eastern Avenue, in downtown Toronto. Over the next few weeks we will be making some changes to the space to get ourselves properly set up. During the renovation we will be available by appointment only, so please email us at info@stacklab.ca to set up a time to discuss your project. Thanks!

On December 20th, we posted the CNC mill update for the Oyster Road Case. Since then, we have completed the project and delivered it to the Neptuno Oysters! This piece provided us with a fantastic learning experience while we worked to resolve the many issues that arise when combining such old material with newer methods of fabrication and form making. We extend our most sincere thanks to our collaborators Studio Kimiis for working with us on this vision. And of course to Neptuno, for their support and patronage.

For more information, or to place a custom order, please email us at info@stacklab.ca

A client recently commissioned us to design and build a kitchen banquette in their new home in the Toronto Bluffs. Our proposal pairs an oblong plywood table and bench with two geometric steel structures. The table base is a hyperboloid comprised of the smallest possible spindles for the load. The bench structure can be thought of as an arch on its side – made up of narrow, skeletal voussoirs. Stay tuned for updates on this project and please feel free to contact us at info@stacklab.ca with questions or comments.

*The schematic diagrams below are representational

We are currently working in collaboration with Strathcona Construction to design and build a custom entry door for a contemporary home in the woodlands of the Forks of the Credit. The idea for the door is that of a vault in the forest – a mechanical system of gears and pins that opens the luxurious interior to the surrounding landscape. The working components – made mostly of bronze, stainless steel and titanium – are encased in thermal glass and steel. The  7.5′ x 3.5′ x 8″ door has internal piston damper actuators that make it very easy to open and shut. To unlock it, simply turn the wheel.

*the interior renderings below are representational.

Please visit our blog for project developments and contact us at info@stacklab.ca with questions or comments.

Have a great holiday!  We double dog dare you!  See you in the new year . . .