Stage 6: Epoxy Resin Version

The first change in the new model is the mold. It has rotation bearing which makes construction substantially faster. It also has the top removed which allows a impression to be made on the seat. 

This iteration of the design has a few improvements. There is an indent on the seat to improve comfort. The legs have been reinforced along the spine and the stool has better rope distribution overall. The Epoxy casting resin is a little more pliable, and will sag over time but smells better and will take pigments.

An option would be to add a plywood seat for added comfort and strength, but this compromises the cleanliness of the design.

Stage 5: Construction Drawings

Note: after consultation with Daniel, I have decided to just make the rope/resin component and ignore the plywood seat for aesthetic reasons.

Stage 4: 2nd Resin Mockup

 20m 3-core cotton rope, 750ml polyester resin.

First prototype that is successfully weight bearing. Reinforced at crossover points with tiny screws. Had intended to clip the heads off for aesthetics, but this was much harder than anticipated. Legs still flex more than I want, may have to abandon that idea.

Stage 4: Full Scale Resin Test

15m of 7mm cotton rope. 250ml polyester resin. 24h curing time. 

End result looks great aesthetically, particularly the pointed legs. However crossover points had weak adhesion and the legs flexed out under load.

Stage 3: 1:2 Scale No. 2

 82m Kitchen twine on same mould as previous mockup.

Very light, reasonable vertical strength but soft under horizontal compression.