Client
Timeline
Services
STUDIO PROJECT
5 WEEKS
SUSTAINABLE HOME & GARDEN
What is
?
It is an environmentally friendly flat-pack birdhouse with at-home tool-free + hardware free assembly
Research Overview
To guide the design decisions, I selected the black-capped chickadee (Poecile atricapillus) as my target species. These small, cavity-nesting birds are common across much of North America and readily use man-made birdhouses. Their specific nesting needs—including entrance diameter, interior dimensions, and placement height—played an essential role in shaping the birdhouse’s form, scale, and features.
Design Goals
Sustainable
Flat-Pack
Intuitive At-Home Tool-Free Assembly
Sketching
Initial ideation focused on exploring various construction methods, with an emphasis on how form could emerge from minimal material manipulation. I brainstormed multiple approaches to joining and assembly, looking for a solution that would eliminate the need for external tools or fasteners. Concepts ranged from rigid slot-together tab systems to soft-shell collapsible forms, always prioritizing simplicity and sustainability.
​
Material research became a central part of this phase. I investigated several biodegradable and lightweight sheet materials, including recycled papers, foams, and cork. Cork quickly stood out for its natural weather resistance, insulating properties, and soft visual texture, which complemented the organic aesthetics of backyard birding. From there, I focused on how cork could become both the structure and skin of the birdhouse.
Designing
With cork established as the primary material, I began developing a construction method that would preserve its structural integrity while meeting flat-pack and assembly goals. I chose to work with natural cork sheets featuring an adhesive backing, which allowed for tool-free bonding of layered components. This eliminated the need for tabs or glue, and kept the assembly process clean and accessible for users.
The form was designed around a double-layered wall system, improving strength and weather resistance while also concealing seams. I created precise dielines optimized for CNC cutting on the Kongsberg machine. Key species-specific requirements were also integrated at this stage, such as a 1 1/8" entrance hole, proper internal depth, and adequate ventilation—all tailored to the needs of the black-capped chickadee.
To enhance both functionality and visual appeal, I designed a cone-shaped cork roof and base made from a single, bendable sheet. Its angled form sheds water efficiently while expressing the material’s flexibility. A paracord rope system was incorporated for suspension and structural reinforcement, splitting to cradle a feeding tray and reconverging to secure the base.
Prototyping
The first prototypes were constructed from Bristol paper to test scale, tolerances, and joinery concepts. Due to the relatively high-cost of cork during the prototyping process, small scale cork prototypes were created to test the material. These mock-ups helped evaluate the adhesive performance and structural integrity when under tension or suspended. I tested how well the adhesive on the cork bonded under pressure and it held up to mild stress during bending and handling. I iteratively adjusted hole placements, rope channels, and assembly sequences based on these trials.
Once proportions were refined, I moved to a full double-layer prototype using Bristol paper using my final die-lines and glue on the adhesive tab. The Kongsberg machine proved highly effective at cutting clean, consistent pieces, allowing me to dial in accuracy at a small scale.
Final Design - Manufacturing Drawings
The final version of the birdhouse was fabricated on the Kongsberg using dielines. Components were assembled by hand using only pressure, demonstrating the accessibility and ease of the design. The paracord was threaded through 3D printed internal loops and secured with a recycled wine cork—acting as a tension lock—securing the structure in place, creating a visually integrated suspension system. 3D printed components were added to the assembly including the feeder and water tray.​
The design is also suitable for various customization options offered to the user regarding material type and color with different parts of the birdhouse; such as the roof, base, and rope—increasing its market viability in addition to it’s dual function as both a birdhouse and feeder.
