MCET 683 Project Report
Table of Contents:
1.0 Executive Summary...............................................................................................................2
2.0 Market Analysis..................................................................................................................... 2
2.1 Industry Overview.............................................................................................................. 2
2.2 Target Market & Customers............................................................................................... 2
2.3 Anticipated Volume & Cost................................................................................................ 2
2.4Competitive Products..........................................................................................................3
3.0 Functional Requirements......................................................................................................3
3.1 Structural........................................................................................................................... 3
3.2 Thermal..............................................................................................................................3
3.3 Chemical............................................................................................................................4
3.4 Other considerations..........................................................................................................4
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1.0 Project Summary
Plastic has become a widely used material across various industries due to its
cost-effectiveness and versatility. This project aims to leverage those advantages in the furniture
industry by designing a plastic frame for a residential sofa. By replacing traditional materials with
plastic, the goal is to create a durable, lightweight, and affordable alternative that meets
consumer demands while reducing manufacturing expenses.
2.0 Market Analysis
2.1 Industry Overview
The furniture industry is a competitive, multi-billion dollar industry. In 2024, the global furniture
market was valued at 568.50 billion USD and is projected to grow in the coming years. The key
factors driving this market are affordability, durability, longevity, aesthetics, and sustainability.
2.2 Target Market & Customers
Due to the inherent cost benefits of plastic manufacturing, this project targets the apartment
furniture market, where affordability is a key consideration. A significant portion of apartment
dwellers—approximately 30-40%—are college students or recent graduates with limited
disposable income, making budget-friendly furniture an attractive option.
2.3 Anticipated Volume & Cost
To gain a competitive edge, the target cost for the frame is set at $200, undercutting the majority
of frames currently priced at $250-400. Based on market trends, the projected annual sales
volume is approximately 12,000 units.
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2.4 Competitive Products
Competitors in this market use primarily wood and metal as means of making these frames.
Competitors include Amazon, Wayfair, Walmart, and Ashley Furniture homestore. They display
simple designs and use of limited materials. Customers of these products have also made
complaints about difficult assembly as well as poor quality.
3.0 Functional Requirements
3.1 Structural
The couch must support seated individuals safely, with each seat rated for 300 pounds and a
total maximum load capacity of 900 pounds. To maintain structural integrity, the maximum
allowable deflection must remain between 1/200 and 1/300 of the total length, approximately ¼
inch.
Material properties were preliminarily selected based on typical values for wood, a commonly
used frame material. These include a modulus of elasticity of 800 ksi and a yield strength of 5.0
ksi.
The couch is expected to endure approximately 50,000 load cycles under average conditions
and up to 10,000 cycles at maximum load. Material selection will prioritize fatigue resistance,
creep resistance, and long-term durability. Additionally, impact resistance will be evaluated in
compliance with ASTM F1561.
3.2 Thermal
The couch is designed to function within a room temperature range of 55–90℉, with a typical
operating temperature of 72℉. Exposure to temperatures will be limited to a maximum of
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100,000 hours over its lifetime. Fire safety standards require low formaldehyde emissions and
compliance with ASTM E1537-22 and NISTIR 8119.
During transportation, the couch may encounter temperatures between -30℉ and 150℉ due to
less controlled environments. However, as it will experience minimal stress during transport,
these variations are not a significant concern.
3.3 Chemical
The couch frame will be fully enclosed by fabric, enhancing its aesthetic appeal while reducing
exposure to chemical and UV degradation. Cleaning products are not a primary concern, as
they are unlikely to penetrate the fabric. However, material selection will account for potential
degradation from incidental, low-volume exposure to cleaning agents.
The frame must also withstand common beverage spills, including juice, soda, and alcohol.
Over the product’s lifetime, it is estimated to experience up to 100 hours of cumulative exposure
to these substances.
3.4 Other considerations
Given that this couch is for residential use, comfort is a top priority in regards to design. This
includes dimensions such as a 20-25” seat depth, 15-20” cushion height, 20” back height, and
ranging from 71-86” wide. Comfort will also be taken into consideration for the arm rests as
many people lean on them. This means load consideration on the arm rest is necessary as well.
Since the couch will be lighter than most commonly seen sofas, in order to keep the couch from
sliding upon usage a coefficient of friction of at least .5 between the material and different
flooring options on the feet is necessary. Cosmetic requirements entail a smooth surface finish,
and neutral color. Finally the target price for the product is under $200.
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