Home | Feed aggregator | Categories | Industrial Design News

Industrial Design News

How to DIY Bentwood Laminations, Make an Adjustable Camera Bag, a Review of Telescoping Levels & More

Core 77 - Sun, 2017-04-30 01:24
Ultimate Camera Bag for Less than $60

Linn from Darbin Orvar designs and fabricates a padded bag for street photographers, feauturing adjustable dividers:

Giant Steel Letters

Laura Kampf gets to use the bending machine she built last week, as she turns steel sheets into a set of large illuminated initials for a friend's wedding:

DIY Bentwood Lamination Coat Hook

Ben Uyeda experiments with laminating veneer sheets to create this bentwood coat hook:

Reviving A Trashed Grinder, And Making A Sharpening Stand

We like watching people design out loud, and here the MacGyver-like Jeremy Fielding does so as he rescues an old grinder from the trash, then devises an adjustable sharpening platform for it.

New Tool: Stabila Telescoping Levels

Ron Paulk takes a look at a cool new tool, Stabila's space-saving telescoping levels:

Discussing Angled Legs

Not a build video, but in this episode of his "Let's Talk Design" series, Chris Salomone gives his take on how to successfully integrate angled legs into a design:


A Self-Adjusting Marking Tool, a Rotating Materials Organizer, Matthias' Last Shop Tour & More

Core 77 - Sun, 2017-04-30 01:24
New Tool Invention: Self-Adjusting Straddle Square

Izzy Swan is coming out with a new line of tools, starting with this clever invention:

Setting Up Shop

April Wilkerson has finally moved, and here she starts setting up her new temporary shop--which she has to share with her husband:

Final Basement Workshop Tour

Matthias Wandel gives us a final tour of his shop before he moves, explaining how he arrived at the layout and what the pluses and minuses of it are:

Bandsaw-Cut Sign

Jimmy DiResta produces an insanely labor-intensive brass and wood sign for a distillery:

How To Install Handrail Posts, Quick And Easy

Who could make a video of fabricating and installing a deck rail post sexy? The Samurai Carpenter:

How to Make a Spinning Shop Organizer

Designing on the fly, Bob Clagett creates a functional, handy storage unit out of scrap pieces:


The Beauty Behind 'Knitted Glass', 1977 EPA Graphic Standards Reissue and How to NOT Spend $2K on an IKEA Bag

Core 77 - Sun, 2017-04-30 01:24

The Core77 team spends time combing through the news so you don't have to. Here's a weekly roundup of our favorite finds from the World Wide Web:

Parametrically-designed folding chair in the 'digital minimal' style, by Carlo Ratti for Cassina.

A free 3d model for everyone who is into 3D printing.

1977 EPA Graphic Standards System reissue.

Epic Windmill Failures!

IKEA wants to make sure you don't accidentally spend $2,245 on their $0.99 bag.

What if your bike made music to make your presence obvious to others? An experiment by Studio José de la O.

A metaphor for life.

100 successful projects, products, and processes currently connecting Berlin with the world.

Knitted glass?

Design Experience That Matters: How to Solve Hard Design Problems

Core 77 - Sun, 2017-04-30 01:24
1. Identify the Problem Clearly

German mathematician David Hilbert said "a perfect formulation of a problem is already half its solution." What is true for math problems is also true for design challenges: without a well-framed problem statement, it's easy for the industrial design and detail engineering stages of the product to move very quickly in the wrong direction.

Your framework for making decisions matters as much or more than the decisions themselves, because the "chaos" of the system makes most outcomes indeterminate (again, chaos theory: "long-term prediction [is] impossible in general"). [Andy Weissman, "The Chaos Theory of Startups"]2. Have a Point of View

At DtM, our framework for making design decision is the "hypothesis of record." For an early stage project like the Otter Warmer, there are a few critical elements of the product hypothesis.

The first component is the product "point of view" (POV), defined as follows by IDEO's Diego Garcia:

A point of view is the set of conscious constraints a design thinker adopts in order to make a specific statement. [...] I submit to you that, as a rule, things that are remarkable are born from a strong point of view. Those that are not remarkable are often the result of a muddled point of view, or no point of view at all. Having a point of view requires making choices among many possible alternatives. Having a point of view means having a vision of what good looks like as a means to make those choices. You can feel it when something was created with that vision in mind. And when that vision was not in play, you can feel the lack of it. [Diego Garcia, "On Anathem and points of view", Oct 2008]

A POV is almost more useful in how it defines what a product is NOT. Great products are very narrowly focused. During the product development process, there is an irresistible temptation to add new features, or to stretch the product's role to cover more users and situations. The POV is one way to fight against scope-creep and the tendency for great narrow ideas to bloat into "one size fits all" garbage.

A DtM POV takes the form: this USER in this CONTEXT has this NEED. The goal isn't to generate deathless prose, but rather a rigorous definition that we can use as a test to answer ambiguous design questions. After a couple weeks of research, here's the latest Otter POV:

District-level hospitals in developing countries that admit newborn patients for 24-hour care, that have reliable electricity, that are staffed by care providers with limited training but who are able to visually assess newborn hyperthermia and hypothermia, that want to prevent hypothermia in newborns for observation or treatment in the neonatal intensive care unit

-- NEED --

a durable, wipe-clean, always-on single-infant warmer that will maintain a 36 degC conductive surface beneath the newborn, that has a user interface and temperature feedback control system that are "hard to use wrong," and that works both in complement with Firefly phototherapy, with conventional overhead phototherapy and as a stand-alone device. 3. Define the Value Proposition

The next component of our hypothesis framework is the product value proposition. Where the POV is concerned primarily with the user, context and needs, the value proposition address the competitive landscape. For DtM to claim that our product is "better", we have to define "better than what". Here is the latest Otter value proposition:

For district hospitals in resource poor areas who want to treat low birthweight newborns at birth rather than risk transporting them to crowded central facilities, Otter is a conductive warming bassinet for thermally stable newborns who are at-risk for hypothermia to maintain normothermia while undergoing other treatments.


Unlike devices that provide a regulated microclimate that are complicated to use and maintain (for example incubators and radiant warmers), Otter provides affordable active warming that is hard to use wrong and easy to clean.

For an excellent reference on writing value propositions, we recommend Geoffrey Moore's Crossing the Chasm.

4. Guide Development with Design Principles

The final component of our current hypothesis framework are the "design principles", a set of qualitative statements we use to guide product development. Where product requirements and specifications are prescriptive (guidelines to follow), design principles are intended to be generative and inspirational.

For example: Kurt Andersen and Graydon Carter created Spy Magazine to mock the pretensions and excesses of Eighties society and its obsession with wealth and social status. Kurt Andersen said that their mission statement for the magazine, aka their "design principles", were: "Smart, fun, funny, fearless." This framework inspired them to create stunts like mailing tiny checks to billionaires to see who would cash them. Bloomberg ignored a dozen checks; Trump cashed every single one, including a check for $0.12.

With each design principle, we'll include some examples that help to ground the idea. Our current design principles for Otter are:

Is effective: prevents hypothermia; improves clinical outcomes; meets international standards
Looks effective: looks like a trustworthy modern medical device; looks warm; appears intuitive
Context-friendly: compatible with both rural context (cost to buy, own) and other newborn clinical interventions
User-friendly: hard to use wrong, facilitates mother-child bonding, provides good patient visibility

Check back in a few weeks as we update other key components of the Otter hypothesis!

Automated Dispensing Cabinets that Prevent Medication Mix-Ups

Core 77 - Sun, 2017-04-30 01:24

Designed to easily optimize inventory, minimize stockouts, and reduce missing doses with smart drawers that have 50% more capacity compared with similar units on the market. The cabinets securely store medications with durable metal locking lid drawers, and prevent medication mix-ups with the integrated Medication Label Printer.

View the full content here

Here's What Went Down at Sketch Jam 2017

Core 77 - Sun, 2017-04-30 01:24

This article originally appeared on Coroflot, Core77's Design Job site. Visit their blog for more insight on working and recruiting in the creative professions.

Well...that was fun. The first ever Sketch Jam is officially in the books. We weren't sure what to expect, but based on the positive reactions from our judges, competitors and audience, we think it's safe to say it was a success. Sixteen competitors, five judges, and four rounds meant lots of seriously cool sketching happening.

Of course, Sketch Jam wouldn't have been possible without all of our talented competitors, who showed off enough enthusiasm and skill to keep the audience entertained throughout the event.

In case you missed it, here is the full list of competitors:

Nick Daiber
Sean Nemoto
Andy Thaemert
Anna Myers
Christopher Hanks
Cesar Idrobo
Eric Von Holten
Jared Rhind
Louis Toussaint
Mengyan Li
Jimmy Nguyen
Vito Morbidini
Dewayne Dale
Jeffrey Brummer
Jeff Thrasher
Bianca Jordan Cha-Camp

So many sketches

The four competitors who made it the third round were Nick Daiber, Sean Nemoto, Andy Thaemert, and Anna Myers. The goal for that round was to create an effective rendering of a specific kind of product that was named at the beginning of the challenge. The catch was that each competitor was given a pack of mystery drawing tools while artfully using all the drawing tools given to you. These included highlighters, metallic gel sticks and art crayons. Here is what the sketchers came up with:

Anna Meyers Sean Nemoto Nick Daiber Andy Thaemert

Following an intense deliberation from our judges, it was decided that Nick Daiber and Sean Nemoto would be the two finalists to face off head to head in the fourth round. For this one, each competitor was given twenty minutes to render their favorite product to sketch (their 'go-to' as it were) using all of the tools in their kit and tricks in their bag to create a beautiful, finished product rendering.

Nick Daiber, left, and Sean Nemoto right

Finally, Nick Daiber was chosen as the winner and he received a Wacom Cintiq 27:

This guy won a Wacom!

All in all, everyone who showed up to view and participate in Sketch Jam had a blast. Special thank you Outlier Solutions for filming the event and to our sponsors: Wacom, ComedySportz, Pensole, Fort George Brewery We're already looking forward to Sketch Jam 2018!

Did you miss out on the action? Fear not! You can watch the entire stream here.

We'll be posting more post-event coverage soon, so stay make sure to follow Coroflot on Facebook, Twitter, and Instagram for more Sketch Jam updates!

Design Job: Take it Sky High! AERIA Luxury Interiors is Seeking a Aircraft Interior Designer in San Antonio, TX

Core 77 - Sun, 2017-04-30 01:24

AERIA Luxury Interiors is the VIP completion division of VT San Antonio Aerospace, Inc., an affiliate of ST Aerospace. We specialize in the design, manufacture, installation & certification of private VIP interiors for Boeing and Airbus aircraft. AERIA's highly personalized, luxury interior environments are found in aircraft owned and operated

View the full design job here

The "Pan Am Experience:" Luxury Dinner, Circa 1970, Served in a Recreated 747

Core 77 - Sun, 2017-04-30 01:24

While the experience of driving is better today than it was fifty years ago, flying commercial has become worse. That has given rise to a rather bizarre, nostalgia-driven restaurant in Los Angeles: The Pan Am Experience, where people pay $300 a head to sit in a reconstructed 1970s-era 747 and have a 4.5-hour, six-course meal with caviar and booze.

The experience is meant to evoke the days when flying was a luxury and chances were slim that you'd get your teeth knocked out on the tarmac in Chicago. The stewardesses carve your food up for you in the aisles while you studiously avoid eye contact.

Speaking of stewardesses, judging by the photos, one of their hiring prerequisites is apparently physical attractiveness. As part of the experience they also put on a mid-meal "fashion show" where they walk the aisles in authentic flight attendant wear from different decades.

Copies of magazines from the '70s are on-hand, and there are even prop cigarettes that blow smoke.

What we'd love to see, in another 50 years' time:

The United Experience

- The evening begins with a 2.5-hour security line

- Patrons may be barred from entering the aircraft due to their apparel

- Others are randomly selected for ejection, but can opt to fight against mixed-martial-arts-trained interlopers in an effort to retain their seat

- Oversized pets are loaded into the cargo hold, while passengers take bets on which will and will not live through the experience

- Customers can load cowboy hats or bulky coats into the overhead compartment, to enjoy the experience of inconveniencing paid actors who are loudly told they must check their carry-on because there is no more room

- Customers can suddenly recline their seats in order to shatter a laptop sitting on the tray table behind, producing a satisfying crunching noise

- Customers are encouraged to remove their shoes and socks, and extend their feet into the row ahead of them

- Male customers are encouraged to dispense with aim while using the lavatory

____________________________

The Pan Am Experience is booked up until July, and they're eyeing Las Vegas and New York for second and third locations. You can learn more about the company's origins in this AdWeek article.

A Reciprocating Saw Blade That's Designed to Break

Core 77 - Sun, 2017-04-30 01:24

Recip saw blades are typically thrown out when the teeth near the tang become dull—even when the ones near the tip remain sharp and new. The traditional way around this was to make use of the saw's adjustable shoe, which can shift cutting to a fresh set of teeth an inch or so out from the clamp that holds the tang.

Most of the wear on a blade occurs an inch or so out from the shoe.

But what do you do when your saw does not have an adjustable shoe or the blade is so long the shoe lacks the throw to bring all of the teeth into prime cutting position? 

A second tang is punched into the center of the body.

Someone at DeWalt asked that question and came up with the idea for the Breakaway Blade, which is punched through the body in such a way that a worn blade can be broken in two to expose a second tang.

A 9-inch blade being snapped in two. The piece on the left is essentially a new 6-inch blade.

With the second tang in the clamp, a fresh set of teeth can be used for cutting. The design is akin to that of the blade in a snap-blade utility knife.

A 6-inch blade snapped in two.


DeWalt is not the first company to make a recip blade with more than one tang. Lenox makes an abrasive blade with tangs on either end. It works for that blade because with abrasive grit there is no direction of cut. Toothed blades cut on the in-stroke, so it wouldn't work to put a tang on both ends.

Breakaway blades come in 6- and 9-inch lengths and are currently available for cutting metal: steel and copper pipe, conduit, metal studs, and the like. I doubt these will be adapted to wood-cutting applications because the opening through the center will weaken the blade and possibly cause it to kink if it binds. Binding is less of a problem with cutting metal than it is with wood. Also, it's possible to cut wood and drywall without the shoe against the work—making it easier to use more of the teeth. It's harder to do this with metal.

It makes sense DeWalt would be the company to come up with this design. Why? Because most recip saws have adjustable shoes but many of DeWalt's do not. The availability of the Breakaway Blade makes up for the lack of that feature. And the ability to "start new" with a partially worn blade would be of value to those whose saws have adjustable shoes by allowing them to utilize even more teeth than before.

Hand Tool School #29: Plywood Tearout? Grab a Hand Saw

Core 77 - Sun, 2017-04-30 01:24

You may have heard that you can't cut plywood with a hand saw. That's a myth.

Using a panel saw—10 p.p.i, teeth filed crosscut—on this 3/4" Walnut plywood produced not only a perfectly straight and square cut, but no tearing or fraying of the super-thin face veneer either.

Pictured here is the back side of the cut, which usually tears the most as the saw exits the wood. I have gotten much worse quality cuts from my old table saw and even my fancy Festool track saw.

Here is a shot of a crossgrain cut on the face veneer that shows a negligible difference to the cut quality.

I made these cuts with no blue tape on the cut line, no zero clearance support underneath, just a well-tuned saw with a tooth geometry well-suited for the task at hand. (In this case 20° rake, 15° fleam. The relaxed rake eases the saw teeth into and out of the wood, and the fleam creates tiny little knives that slice across the grain making for very clean edges to the kerf.) However I urge you not to focus on this as the exact formula for a plywood saw but experiment for yourself. I'm sure even better results could be had if I wanted to create a plywood saw, but I would rather keep this little guy more of a fine finish blade than anything more specific.

If you're unfamiliar with terms like "rake" and "fleam," stay tuned and I'll produce a post explaining saw tooth geometry.

_______________

This "Hand Tool School" series is provided courtesy of Shannon Rogers, a/k/a The Renaissance Woodworker. Rogers is founder of The Hand Tool School, which provides members with an online apprenticeship that teaches them how to use hand tools and to build furniture with traditional methods.

Reader Submitted: An Interactive Light that Fights... Jet Lag?

Core 77 - Sun, 2017-04-30 01:24

For people facing jet lag, Jeggo offers a preventative and treatment strategy: It automatically synchronizes with a 'jet lag plan' to adjust your body clock to the destination time, and it reminds you when to avoid or absorb light through light effects mimicking sunrise and sunset. By tilting the reflective panel or using the remote control, you can also play freely with natural lights and sounds, such as rain, leaves and birds, to ease stress and feel more relaxed.

Jeggo can be used either at home or as a special service in a hotel room. The personal portable controller, covered with felted wool, is soothing to the touch and easy to carry around. You can fiddle with it anytime, anywhere. It is an attempt to alter the experience of a medical device and transform the serious treatment process into an aesthetic pleasure. It also demonstrates how people could interact with lights in different physical and experiential ways.

View the full project here

How to Add Metal Inlay to Wood

Core 77 - Sun, 2017-04-30 01:24

Adding metal inlay is a nice way to provide visual pop to wooden objects or furniture:

The art of inlay is something that used to take decades to master. Now, with digital fabrication tools--or heck, maybe even a trim router with a downcut bit guided by a steady hand--the cutting part goes a lot quicker. However, that doesn't mean the work can be taken lightly. As Instructables user Ninjosh shows, there's still a fair bit of manual labor and finessing involved:

"Inlays are a great way to set your work apart in a crowded market," writes Ninjosh. If you'd like to give it a try yourself, he's laid out a comprehensive Instructable listing all the tools you'll need and offering plenty of helpful advice, including the all-important, time-saving what-not-to-do's. Check it out here.


A Brilliant, No-Mess, Vacuum-and-Water-Based Dog-Washing Machine with a Fatal Flaw

Core 77 - Sun, 2017-04-30 01:24

Here's an interesting example of a company evolving new products around a central idea: Bissell got their start in the late 1800s producing carpet sweeping devices. By the 1950s they'd branched out into carpet-cleaning contraptions, and in the 1970s, carpet deep cleaning machines. In the 2000s, vacuums targeting owners of fur-shedding pets. Now they've combined the latter two categories, adapting a carpet-cleaning machine to harmlessly wash dogs.

As an owner of two dogs, I have been through the exact hell depicted in this video for the Bissell Barkbath:

The Barkbath, if it works as advertised, would be worth every penny of the $150 asking price, versus paying professional groomers to do it. Isolating the mess to the inside of a tank you can pour out, and obviating the need to scrub your entire bathroom down every time you wash your dog(s), would be a huge boon.

My only concern is that the unit is essentially a vacuum—which produces the exact type of noise that most canines find distressing. There's no way the more skittish of my dogs would come anywhere near this thing, long hose notwithstanding. My thought was to buy one of these and construct some sort of soundproof box to keep it within. However, while similar hacks exist for pancake air compressors, they are bulky fixes and care must be taken to ventilate them properly. The storage space and set-up required might outweigh the benefits.

What this product is begging for is noise-canceling technology. While that would raise the price drastically, I bet it would still find a ready market.

Design Job: Made in Detroit! Shinola is Seeking a Senior Digital Designer in Detroit, MI

Core 77 - Sun, 2017-04-30 01:24

The Senior Digital Designer is a multi-medium designer that will execute a range of graphic assets across many areas of the business including web, motion and experience design. The digital designer will work directly with the digital art director and digital team in our Detroit office to ensure projects meet

View the full design job here

Live from Portland – Coroflot's Sketch Jam

Core 77 - Sun, 2017-04-30 01:24


Watch it live in this very post, or catch it at Coroflot's Facebook page.

It's getting hot!


Tools & Craft #44: We're Hosting the Festool Road Show This Saturday in Brooklyn

Core 77 - Fri, 2017-04-28 00:16

I like to talk about tools and craft period, so I try not to make these posts too sales-like. But at the same time I do sell tools for a living, and Core77 has covered Festool a fair bit, so I thought this was relevant.

This Saturday, Tools for Working Wood is hosting the Festool Roadshow in Brooklyn. This is where the company sends a giant trailer full of tools and demonstration workstations so that people can try them out and ask questions of the dedicated trainers they send.

It's also a great opportunity to meet with our own knowledgeable TFWW sales staff, as we ourselves use Festool to construct our display cases and furniture. Talk with them or us about service, availability, speed of delivery and our own experiences with the brand.

We'll have on hand new tools for 2017, including the new knockdown Domino connectors (which Core77 wrote up), and of course we'll have all the saws, sanders, drills, dust extraction systems, et cetera. In my experience these products really do make work more efficient, more accurate and cleaner, which is why I sell them.

The event is of course free, and we'll also have loads of free food, beverages and gift bags for attendees. (If your family doesn't want to come with you, read the two paragraphs down at the bottom.)

Details:Saturday, April 29th
10am - 2:30pm
112 26th Street, Brooklyn, NY

Parking is available under the expressway. The subway (R train to 25th Street in Brooklyn) is only 2 1/2 blocks away. We're not far from the Long Island Rail Road Atlantic terminal.

By the way, we know that a lot of you are coming from some distance. Whether you come alone or bring your family, Green-Wood Cemetery is three blocks away; the entrance is on 25th Street and 5th Avenue, and the cemetery, which was set up to be park-like, should be looking lovely. It is considered one of the most beautiful cemeteries in the US. For any members of your family who aren't interested in Festool, it would be a wonderful walk and some coffee and pastry at the bakery across the street from the gate. 

Rossman's - the best vegetable stand in Brooklyn is at our corner. A few blocks north is Liberty View Plaza, with a Bed Bath and Beyond and other stores. A few more blocks north in Industry City, with its fancy food court and maybe the Brooklyn Flea. After the Festool show there are many things to do in Brooklyn for the whole family from going to Junior's for cheesecake, visiting the botanical garden, zoo, or carousel in Prospect Park, or a museum, and then having a fine dinner at any one of loads of places (ask us where - we have opinions!). A trek to Brighton Beach on a Saturday evening can result in some awesome food shopping and fine Eastern European dinners.

___________________

This "Tools & Craft" section is provided courtesy of Joel Moskowitz, founder of Tools for Working Wood, the Brooklyn-based catalog retailer of everything from hand tools to Festool; check out their online shop here. Joel also founded Gramercy Tools, the award-winning boutique manufacturer of hand tools made the old-fashioned way: Built to work and built to last.

Less is More with This Modern-Day LED Chandelier

Core 77 - Fri, 2017-04-28 00:16

The form factor of chandeliers has grown ever bulkier since its first iteration. What started out as a simple overhead platform to hold candles has steadily grown more ornate, gaudier and heavier. The addition of incandescent bulbs and glass diffusers has eliminated the form-follows-function elegance of the original design.

Now that LED technology has arrived, there is an opportunity to do more with less. As an example, industrial designer Peter Bristol has collaborated with Brooklyn-based studio Juniper to create the minimalist Thin Chandelier:

Made from precision-machined 1/2? brass tubes, the twelve arms can be swiveled, folded and stretched into a myriad of biomorphic and geometric arrangements, each articulating moods ranging from dramatic to playful. The decorative chandelier can be manipulated into varying looks, styles and sizes, ranging from one to ten feet wide—creating infinitely flexible configurations that allow it to adapt to the style of its environment. The chandelier is available in raw brass, satin nickel or an oxidized brass finish.

As with Ron Gilad's Dear Ingo task chandelier, we'd love to see the design upgraded with some user-friendly way to manipulate the arms, either in concert or separately, into various positions. There are significant technical challenges, but we think remote control is the way to go.

An Accurate and Automatic Device for the Detection of Chemicals on Food Produce

Core 77 - Fri, 2017-04-28 00:16

Today, scanning for food contaminants, such as pesticides, can only be done using equipment that is: expensive to buy, expensive to operate, immobile, requires skilled personnel, and does not supply immediate results. The food industry, from farmers, producers, handlers, regulators and retailers to consumers, is in need of a better solution.INSPECTO is an innovative startup company aiming to revolutionize the process by producing an accurate, portable, affordable, quick and automatic device for the detection of chemicals on food produce, both liquid and solid.

View the full content here

How to Dip Your Foot Into the Design Entrepreneur Pool: Make Useful Components, Not Finished Pieces

Core 77 - Fri, 2017-04-28 00:16

If you're not ready to be a full-blown designer/builder, there is a way you can ease yourself into the marketplace. Lately I've noticed a bunch of people are fabricating items to sell on Etsy that are not finished products, but complementary components.

Some examples: Slovenia-based LeatherEU sells these handsome vegetable-tanned leather pulls and binding hardware:

Vermont-based ThirteenColonies produces different designs and heights of wooden legs, in Cherry and Maple, that have threaded rods that match Ikea sofas. The idea is that end users can upgrade the look of their Karlstad, Soderhamn, Sater, Klippan, Ektorp sofas and more:

Maryland-based ChristianWoodsTM sells 4'-long edge-glued pine panels, and rounds of different diameters, all for cheaper than I can buy them at my local lumber supplier. (You'd have to factor your local shipping cost into this, of course.)

Philadelphia-based PhillyFabrication welds up different sizes of hairpin legs made from U.S. steel:

Like suppliers to the auto industry, these folks are tooled up to efficiently produce simple items that others can integrate into larger projects. If you're not ready to launch your own line of finished objects yet, this might be a good way for you to get started and get some crucial fulfillment experience under your belt.