Project Background and Development

Early Stage – The Birth of an Innovative Concept

The journey of the SMUPI project began with a humble idea – to create pillows that could attach themselves using hidden magnets. Inspired by the Roche Bobois Mah Jong design, which resembled old mattresses in a square format, we aimed to offer a more versatile and user-friendly solution.

However, after visiting homes with similar furniture designs and engaging in conversations with the owners, we identified a critical limitation. The Mah Jong design posed challenges in terms of limited possibilities for customization and the arduous process of removing the covers, which were secured by yarn bows and intricate stitching forming piped edges. We recognized that this limitation was unnecessary, despite appreciating the charming “seasoned” look of old wool mattresses. A cover in a smart mattress should be easily removable for periodic washing, and the Mah Jong design hindered this requirement.

To address this limitation, we explored various methods and materials. We try to place magnets positioned along the edges, hidden beneath the fabric, provided a practical solution. To ensure self-alignment, we implemented spherical magnets, which proved to be a brilliant innovation.

However, we encountered challenges along the way. The initial magnet strength required to hold the backrest caused fabric damage, resulting in holes. To reinforce the fabric, we experimented with leather patches placed between the magnets.

Additionally, the method of creating cavities for the magnets in the polyurethane foam that comes in large blocks that need to be formed using incandescent rods produced toxic fumes, rendering it unsuitable for large-scale manufacturing.

We transitioned from natural wool to artificial polyurethane, recognizing the need to define material choices as an internal policy for our core product with the needs to care for our earth we discarded even polyurethane to move to natural latex . Derived from natural latex extracted from the Pará rubber tree, latex is commercially grown in equatorial regions of Southeast Asia and Africa. This material, processed through foaming and vulcanization, proved to be an exceptional upholstery material. Moreover, latex is biodegradable, compostable, and environmentally sustainable.

To achieve partial industrialization, we developed a modular pillow design in standard units of 22 cm cubes. These pillows incorporated a series of holes in all three axes, allowing for adjustment and support customization. By inserting bamboo sticks into these holes at varying levels, users could modulate the springiness and bounce of the pillows by establishing a structural semi rigid plane on the foam .At the vertex of the cube, we incorporated cavities to house the soft rubber containers that contain the magnets. The magnets are positioned 4 centimeters inside the upholstery, and when two pillows are placed in proximity, the magnets slide near the surface inside the containers and hold the pillows together. All this holes in the foam are formed during the vulcanization inside an engineered mold that made this process ideal for production.

The Universal Stage – Expanding to a Furnishing System

Recognizing the need for an elevated platform for the pillows, we embarked on designing a solution that would keep them off the floor. Our team conceptualized a rigid board with spherical cavities, carefully positioned to accommodate the magnets within the board itself. To ensure durability and a sleek aesthetic, we covered these cavities on the board with a stainless steel plate, creating a reliable layer to support the pillows while adding a touch of elegance to the design.

As we explored this concept further, we had a breakthrough. Inspired by the integration of magnets within the boards, we devised a solution to utilize the magnets in holding the boards and the cabinets together. By placing the magnets inside the board’s niches and securing them with small stainless steel plates, we achieved a secure connection that allowed for easy assembly and disassembly. This innovative approach marked the second stage of our development process, as we realized the potential of creating modular boards and cabinets.

Utilizing CAD software, we delved into experimenting with small modules derived from the basic cube shape. This exploration revealed the versatility of our system, as we discovered that these modules could be arranged to form various furniture shapes. The key to this innovative design lies in the strategic placement of magnets along the borders and corners of the boards, as well as the edges and vertexes of the cabinets.

By incorporating magnets in these specific locations, we ensured a secure and seamless connection between the boards and cabinets. The magnets act as invisible anchors, holding the components together while allowing for easy assembly and disassembly. This magnetic integration not only enhances the stability and durability of the furniture but also enables the freedom to create custom layouts and configurations.

The SMUPI system harnesses the power of magnets and modular design to offer an unparalleled level of flexibility and adaptability. The magnetic connection provides a strong and reliable bond, guaranteeing stability while offering the convenience of easy customization.

The Enhancement Stage – the Magnetic Cost Limitation – the Mechanical Clip Solution

Due to the price surge of rare earth elements, such as neodymium, caused by factors like the COVID pandemic and increased demand from the automotive electric industry, we faced challenges in maintaining affordability for the general market. To ensure accessibility while preserving the interoperability with the pillows, we explored alternative solutions to solely relying on magnets for connectivity.

After considering various options, we developed a unique key mechanism that could be manually inserted between the rounded edges and borders of the original design, securely holding the spherical magnet in place. To achieve an elegant, tool-free, and reliable connection, we designed a double spire clip made of strong stainless steel wire. This clip was carefully configured to provide both strength and aesthetic harmony within the narrow available space.

To further enhance the design, we incorporated a continuous slide path along the metal plate, which could be filled with a rubber material. This rubber, available in matching colors or neutral tones, served multiple purposes. It not only created a smooth and uniform surface between two contiguous components but also concealed and protected the metal clip. Additionally, a wire or small cord could be threaded through the modules at angles below 180° to secure their connection.

With this innovative solution, the magnet became an optional component for connecting boards and cabinets, while remaining essential for the attachment of pillows. The magnet’s functionality was extended to act as an invisible hinge for boards that could be utilized as cabinet doors. This adaptability allowed for the construction of large cabinets using smaller box modules as structural elements, with boards serving as external walls and hinges. As a result, SMUPI furniture offers exceptional versatility, retaining long-term value and investment potential compared to traditional single-function cabinets.

Furthermore, we anticipate that as end users change the configuration of their modules to adapt to new homes or uses, some modules may no longer be needed while others may be required. This dynamic presents an opportunity for high resale value, which will be highly appreciated by owners. To facilitate this process, our website can serve as a platform for the exchange and redistribution of used modules, promoting sustainability and fostering a circular economy. Through this platform, individuals can contribute to minimizing waste and maximizing the lifespan of our products, ultimately reducing their environmental footprint.

Conclusion – The Future and the Finishing Touch

As we reflect upon our journey, exploring various prototypes and construction techniques, we have discovered alternative approaches to ensure the success of industrial production in terms of manufacturing cost, material availability, and manufacturing processes. Each iteration of development has been subjected to thorough scrutiny as we strive to surpass existing products in the market, with the firm belief of setting the standard in universal modular interiors for the benefit of our visionary end users.

Throughout the process, we have encountered the need to make compromises in dimensional functionalities, carefully selecting measurements to achieve our desired standard. In assessing these challenges, we acknowledged that certain desires could impede component construction. However, we made deliberate choices and modifications to transform this project into a tangible reality. These compromises were essential to employ specific manufacturing techniques that guarantee the industrialization of metal components, pillows, and rigid modules.

To ensure accessibility and efficiency, we meticulously scoured the market for readily available parts, such as magnets and the rubber elements that secure them within the pillows. Our deliberate choice of a 19 mm diameter spherical magnet was crucial in providing the necessary strength to securely hold the pillows while supporting their average weight. Numerous subsequent measurements directly depend on this central consideration. For instance, the 22 mm thickness of the board directly correlates with the magnet’s specifications, and the semicircular profile of the metal, with an external radius of 11, further emphasizes this dependency. Our choices have been intricately interconnected, guided by consequential relationships.

Throughout this journey, we have relied on the expertise of the engineers we collaborated with, visiting various factories and diligently seeking answers to manufacturing dilemmas. We have adapted our designs in accordance with the chosen techniques, ensuring continuous refinement. Approaching the third year of this undertaking, we remain confident in our readiness to proceed, recognizing that each new development presents unique challenges to overcome.

Our commitment to delivering the best product for the future of our planet remains resolute, serving as an unwavering promise. While we may need to make certain compromises to ensure profitability, the ultimate choices made are akin to political decisions. The final touch lies in the hands of our esteemed end users, who will determine the surface decoration, fabric, color, pattern, and other customizable elements. Embracing individuality, our standard is designed to empower architects, designers, and end users alike, fostering collaboration in exploring new uses and markets.

We envision the application of our modular concept in diverse industries, ranging from luggage design to integrating appliances for entertainment or kitchen purposes. The versatility of our system enables adaptable spaces that can cater to various needs and preferences.

With unwavering commitment to innovation, sustainability, and user-driven design, SMUPI is poised to shape the future of interiors. As we embark on this remarkable journey, we invite you to join us in revolutionizing the way we envision and create living spaces, where possibilities are limitless, and individuality reigns supreme.

The future awaits, and the finishing touch is yours to make.