Hi there!

I'm a student industrial product development at Howest. For a school assigment, I had to design a flat packed item, and I came up with a flower pot idea. In this blog I will show you why and how its made.

Flat pack, whats that?

Flat pack is a way of designing and transporting items in a way they consume less space. This way you can be more efficient,save money and have less emissions per product in transport for example. You are also able to store more and better. Less space needed, more space available.

Step 1: Materials and Tools

For this project, you'll need:

Materials and tools:

Durable outdoor wood 6 mm thick, 150 mm wide, and about 1200 mm length
Strong multi-material glue
2x M6x24 bolt
2x M6 nut
6 mm wood drill
Countersink drill bit

Drill
Saw
Linseed oil
Terpentine
piece of cloth
Cutting knife

Step 2: Step 2: Cut Wood in Pieces

We need three sizes of pieces:

2x 12 cm x 15 cm
2x 30 cm x 15 cm
1x 30 cm x 12 cm

Start by measuring one piece and cut one out at the time. A saw blade also has a width!

You can use to tools you have standard at home: A saw
I used a table saw. Cut at 90° angle!

Step 3: Step 3: Cut & Drill Pvc Textile

When you are ready with the wood, you can make an outlay of all your pieces.
Then, measure how big and wide the wood reaches. You'll cut a rectangle of this size (Width x Height). 60x45cm

Make line out of cutting lines rectangle
Try to cut out the rectangle in one time, or it might look messy with all the fibers coming loose.
Place hole marks for bolt entry (drawing)
Carefully, and SLOWLY drill the holes. (If u do this fast the pvc will get into your drill together with your finger and this is very dis advised.

Step 4: Step 4: Glue Wood to Pvc

First you'll need to draw the lines of where to wood needs to come.

Then, sand down the surfaces with sanding paper (P80-240)
Do the wood, but especially the pvc! If you want glue to stick, this will have to be done real good.

Next, Apply glue to the surfaces. It is advised to use latex gloves, your hands will spared from sticky glue mess!

When you are finished, let the piece dry at a place where its not too cold, not too hot, and not too damp. (+8°C - No rain/Moist).

Step 5: Step 5: Apply Protective Coat

Now its time to add a protective coat. This coat will keep your color of your wood and give it a warm look. It will also prevent water from entering the wood.

Use a small cup to mix 1/3 Terpentine (toxic) and 2/3 of linseed oil.
Then, dip a small piece of cloth in the mix.
Rub the wet cloth over the wood surface, until the mix is spread nicely. The surface must get a "wet look".
If you apply too much, simply use a clean piece of cloth in order to remove the excess oil. Now you can rub it dry. The rest of the oil will slowly penetrate the wood and give it its protection and color coat.