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'Kona' Coffee Table System | Flat-Pack Furniture Design Prototype

Project type

Furniture Design

Date

November 2025

Location

Ahmedabad

Kona is a modular furniture system built around a precision-cast corner bracket that standardises how legs, stretchers, and tabletops connect. The project demonstrates a scalable, flat-pack table architecture with interchangeable materials, repeatable manufacturing, and user-serviceable assembly. Optimised for durability, configurability, and industrial production, Kona shows how a single engineered corner can generate an entire family of coffee tables, side tables, and work surfaces.

Assembly

Early Concept Sketch

Initial Concept - First Prototype

This 3d printed prototype was made to test how one corner bracket could hold the side stretcher panel and the legs via bolts.

Second Prototype

3d printed prototype made in scale, with a slightly different bolting of the leg.

Stretchers and legs made using corrugated cardboard sheet.

2 bolts at different angles.

Third Prototype

Testing actual aluminium section on a printed corner

Assembling the 4 corners and 4 stretchers.

Final Prototype

This model was made to see how the corner would look like in true scale.

There were grave errors on the dimensions of the span and height that were later corrected.

The top and legs are 5mM corrugated cardboard while the stretchers are 1.5mm buff board. The corners are 3d printed in pla. Duct tape has been used to assemble all the components.

Modular coffee table prototype showing wooden top resting on metal frame during assembly

1:4 Model

A model with all the components made to be interchanged, attached and detached to show the flexibility of this sytem that allowed for customisation in size and colour.

Scale model of modular coffee table system demonstrating interchangeable legs and frame geometry

First Cast Corner

Cast metal corner bracket prototype mounted on wooden leg for structural testing

Mid Semester Review

Got feedback regarding the bulkiness, manufacturing constraints, usage assumptions and scale related iisues.

Design studio setup with furniture system drawings, prototypes, and material studies on display

New Corner Design

Getting the smaller and low profile corner cast.

Broken sand mould pieces after metal casting process for furniture corner brackets

Making Corner Section

Hand-held cast aluminum corner joint showing interface between metal bracket and wooden leg

Tested out new bolting

Table leg prototype with square wooden top plate and central metal connector

Visualising in VR

CNC milling process shaping wooden tabletop component for modular furniture system

Sectional Model Making

Metal machining operation drilling cast aluminum corner bracket

Underside of the corner, showing the rivets used to attach the stretchers and the bolt used to attach the leg.

Detailed view of metal corner bracket connecting two wooden frame members

Left side - Protruding Leg, Matte PU Coat, Stainless Steel Countersunk Bolt.

Right Side - Flush Leg, Danish Oil Coat, Black Low Profile Bolt.

Wooden leg prototype with precision-drilled holes for modular table assembly

Disassembled Sectional Model

Wooden stretcher and frame components laid out for modular furniture construction. Sectional Model.

Making Cast Bracket

Sand Casting

Manual sand mould shaping process using hands and tools for casting metal parts

Traditional sand compaction using feet during metal casting mould preparation

Molten metal pouring into sand mould for aluminum furniture corner brackets

Raw out of sand casting

Freshly cast aluminum corner components removed from sand mould

Grinding

Post-casting metal trimming and cleanup using bench vise and hand tools

Drilling

Drill press operation refining holes in cast aluminum joint component

Precision drilling of aluminum corner bracket using vertical drill machine

Polishing

Grinding and surface finishing of cast aluminum part using rotary wheel

Powder Coat Finishes

White prototype of modular corner connector tested for form and ergonomics

Black-finished corner joint prototype showing final material and surface quality

Making the Tabletop

Sourcing White Oak Planks fpr Top

Stacked wooden planks prepared for furniture frame and tabletop fabrication

Making Biscuit Joints

Power planer used to level wooden planks for modular table components

Glueing biscuits

Hand glueing wooden planks for tabletop surface.

Clamping Planks

Clamping process holding wooden tabletop panels together during glue-up

CNC Routing

Sanding (80, 120, 180, 240 grit)

Orbital sanding of tabletop surface to prepare for finishing

Staining Top

Making Side Stretchers

Marking on the Sheet

Manual edge finishing of wooden component using hand tools

Bending Sheet

Industrial thickness planer smoothing wooden boards for furniture production

Checking for Alignment with Corner Bracket

Measuring and inspecting wooden table component during fabrication process

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