Flying table has definitely become one of my most beloved projects. It required a bit of thinking as I did not like any of the ideas or plans available online. Ultimately, I have designed my unique version that combines tensegrity, woodcraft, epoxy casting, and fine inlays.
Oakwood tensegrity coffee table with epoxy and inlays
In the following article, I will reveal basic principles and know-how so that you will be able to design and craft your own piece.
Table of Contents
Tensegrity principle
Tensional integrity or floating compression is a structural principle based on a system of isolated components under compression inside a network of continuous tension, and arranged in such a way that the compressed members (usually bars or struts) do not touch each other while the prestressed tensioned members (usually cables or tendons) delineate the system spatially.
Wikipedia
Concepts based on the simultaneous application of tension and compression forces are, in fact, not so uncommon. Our own bodies also consist of a continuous network of muscles and connective tissues, while the bones provide discontinuous compressive support, whilst the nervous system maintains tension in vivo.
Tensegrity in woodworking
For our purposes, we will apply these principles in quite a simple form. Most basic structures you might see online are like:
source: grabcad
In general, it consists of separated top and bottom structures. Tension is applied via the central point, while links at outer corners define the final distance of both structures.
And searching further, you could find some projects already intended as furniture, usually using rough wooden or metal frames.
source: whiteclouds |
source: YT, The Q channel |
Designing my own flying table
Somehow, nothing that I found online did intrigue me. I was looking for an eye-catching but stable design that could easily become a living room centerpiece. So, I started with a few hand sketches followed by 3D models in Sketch Up, defining the position and shape of the top and bottom desk and central tension points
In the end, the middle variant won
I knew I wanted to use multiple (finally 3) cental tension points for improved table stability (red arrows) and four counter-tension links in each corner (blue arrows). When there was a chain connecting the top and bottom parts, I did not like it as it looked awful and massive, ruining the whole impression. Organic or plastic rope was also not an option due to its stretching. After a few experiments, the best option for such a task was stainless steel high-strength wired rope. Even 4mm steel wired rope has a load limit of almost 1 ton.
Making of the top and the bottom boards
From the very beginning, I intended to combine the project with epoxy resin. Because of continuous tension within the parts, appropriate material hardness is required, so I chose solid oak hardwood as a base.
After flattening the rough oak boards, I prepared the top for epoxy casting.
In the middle of the cast
For the bottom board, I have planned an inlay with a black tree and raven motif. Fine inlay techniques I will definitely share in some upcoming articles. For now, I am using a small hobby CNC Shapeoko 2. Route your inlay path with a V-shape bit. Clean the result and pour the prepared resin mixture.
CNC routed path |
Filled with epoxy |
As the resin on both boards hardened, I flattened them in CNC and cleaned them from epoxy excess.
Flattened boards
Additional channels I routed to the back side of the top desk. Steel inserts are going to hold steel wires as well as prevent the top from bending.
Routing channels for steel inserts
The boards are now ready for sanding and final assembly.
Sanding process
I decided to go for a high gloss finish on epoxy, which is a bit challenging. However, with the right tools, it does not take that much time and effort.
For more information about epoxy sanding please refer to my previous article:
Final assembly surface treatment
In the meantime, I have also cut and drilled the rest of the wooden parts for the table
Additional experiments with different steel wire connection elements were necessary at this point. It the end, the most robust solution was to use available components used for steel wire fence construction:
Steel wire connector and straightener |
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At this point, I assembled and glued all the smaller parts. For the surface finish, I used Osmo Top Oil, which has certification for contact with food.
Finally, I attached steel wires through the connectors and steel inserts. Straightened them evenly so that tension in every wire was about the same. The long-term load stability of the table was tested at 20kg without any issues, and the short-term load stability was tested at 75kg. However, coffee from a full cup is going to spill if you intentionally start shaking the top desk.
The unique flying tensegrity table is now complete:
I hope I have inspired you and answered some of your questions. If you need additional answers to the topic, feel free to post them in the comment section.
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