Wood Products

LR

Liquid Repair

1Challenge

Develop a liquid wood-repair product and process for a global commercial furniture
manufacturer. Product and process needed to increase efficiency, reduce costs, automate
certain procedures, and meet the highest standards of safety and non-toxicity requirements.

2Objective

Deliver a rapid repair solution that meets all aesthetic and safety requirements, empowers
automation, and is cost-effective. Create a solution that helps the customer meet long-
term corporate growth, profit, quality, and environmental goals.

Rapid repair solution that meets all aesthetic and safety requirements

Rapid repair solution that meets all aesthetic and safety requirements

Rapid repair solution that meets all aesthetic and safety requirements

Rapid repair solution that meets all aesthetic and safety requirements

3Approach

We considered and eliminated a range of other approaches to this challenge

leading us to invent an entirely different way to prepare and repair solid
wood for use in commercial furniture manufacturing. Our hypothesis and
testing methodology included:

Added heat at key stages
of the repair line

Adjusting component ratio to mimic hardness and texture of wood

Experimented to identify

  • – Best materials that meet stringent
    health, safety and environmental
    standards
  • – Ideal cutting tools

Expanded range of defects that could be repaired to increase efficiency

Clear patch to repair wood knots and other defects. Pictures above show after liquid polyurethane product application (left), and after curing and subsequent sanding (right).

Clear patch to repair wood knots and other defects. Pictures above show after liquid polyurethane product application (left), and after curing and subsequent sanding (right).

4Solution

We created a holistic revamp of their entire wood repair process,

including a novel synthetic repair material, that allowed
them to use the same approach but with added automation
and an increased level of precision and quality control. In
short, we delivered the first successful implementation of a
liquid repair upgrade for consumer solid wood furniture.

liquid patch application

liquid patch application

liquid patch application

liquid patch application

liquid patch application

liquid patch application

5Outcomes

Increased efficiency

  • – 13%+ increase in wood materials suitable for use (from 22% to 35%)
  • – New cutting and drilling tools

Decreased environmental footprint

  • – Increased wood-use efficiency
  • – Less product waste

Expanded customer range

Better cost-efficiency

  • – Lower production costs
  • – Lower end consumer price

Patch to repair wood knots and other defects. Pictures above show after liquid polyurethane product application (left), and after curing and subsequent sanding (right).

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