Problem - my sons Lego collection was getting out of hand. Blue bag maxed out and even more clutter created with storage containers and table I added

We were in Ikea one day and saw this table with 3 kids playing happily on it. I thought this is the perfect size for a kids Lego work table.

I had been looking at Lego storage and found this. Great solution for sorted bricks and storage, but not for children. Also, every time you need to get a new piece you need to stand up and pull out a container or you have containers sitting all over the desk.

Then I stumbled upon this on Pintrest when looking at storage solutions. Pintrest is very random.

I made some containers out of cardboard to get an idea of the size of containers I wanted. (initially there would be 4 different widths of container and 2 different heights; but only 2 sizes of the taller containers)

I wanted a smooth transition to easily remove items from the container

I considering adding a sorting area in the middle part of the table, so that you could use the table for sorting as well as working on projects. Also because of the organic nature of play, you need to accept that your work area needs a space to just put some mess while working. Better on the table, than on the floor.

A very rough sketch of the storage container design. (these are personal sketches, no consideration for linework or presentation. only for figuring out form a features). I was concerned with the finger lip and stacking (cutting down shipping costs)

This was the first 3D concept I did. Showing different container sizes & multiple layer stacking.

I had 2 of the smallest storage containers 3D printed. I wanted the containers to feel smooth and look clean. So I decided against adding structural ribs all over it. This is why I choose to 3D print with SLS Nylon, to actually test the structure as well as the feel.

With these prototypes I refined a few details that would have been costly in production. So well worth the $250 cost.

The 2nd 3D Concept with more refinement on how to manufacture it and modifying the table top to include an area to sort Lego.

Showing how the design is modular. When you need more storage containers you can buy another shelf (sold as a kit) and the individual storage containers. You build from the top down. So it starts as a table that you can sit under, then in time turns into a large storage display that you can place along side a work table if necessary.

30x Small Containers

15x Medium Containers

10x Large Containers

6x Extra Large Containers

Top View showing different size containers in use

Top View showing how a combination of different containers would fit together

An idea to personalize the Sorting Area Lid and attract children to the product (the mouth area is the handle used to remove the lid)

Showing the overall product with multiple layers of shelving and showing scale with the Lego Baseplates

Making a physical prototype at home with a Router.

All circles cut out

All routing complete. Inside area used a 45 degree tool and outside used different round over tools.

Sanded, glued and screwed together all parts.

Again, showing scale and that i designed the table to fit 4x 32x32 Baseplates. 

Showing how i planned the storage containers to work with the 3D Printed samples I had made.

The Sorting Lid routed, cut, sanded, painted to look like a Lego Minifig.

Showing how the handle part works. (not the best paint job. I did use kids Acrylic and painted with a paint brush. Cost $0 to make)

Sorting Testing. I wanted to test the Ergonomics of the design before finishing the table. So I set up the table top on top of an existing table and here I am looking at reach. 

This is the current storage system we are using. When the table is finished and if i can make these storage containers, then we will switch over to my design.

After conducting the sorting tests and trying to organise all of my sons Lego; I realized that there are a lot of cases where a very small container would be useful. I was also looking at cutting down tooling costs and combining storage containers. 

I got rid of the small sized container and am only considering the Medium, Large and Extra Large sizes; but I will be adding internal dividers as well as a shelf component that sits on top of the main storage container.

This is the cardboard mock-up I made to look at how many pieces I could store in the mini containers.

I don't want these mini containers too deep or too shallow. As they need to be practical, but at the same time I want storage space below them for larger parts.

I increased the depth of the storage containers from the initial prototype I had made.

I also increased the width of the containers too. But these two decisions were based on slightly changing the diameter of the table to enable the most efficient use of  a plywood sheet when manufacturing. (greatly reducing costs)

Changing the table dimensions to fit all the parts onto 1 sheet of regular plywood. The idea is to CNC the parts, as there are 45 degree angles and some big rounding edges. But it could be Lasercut, then Hand Routed, but that seems like more work.

I had initially thought about putting a Lego brick pattern onto the Mold of the storage containers, but it would have added more complexity and cost to each tool. Also, it would mean that my product couldn't be re-used for other non Lego related industries that might see a benefit to my product. (eg. Jewelry or Fasteners).

Then I considered making stickers that were either blank and fit into a home printer, or were printed with lots of generic Lego brick types. (but there are over 7000 types of Lego Bricks!!!)

I finally stumbled on the idea of making the brick pattern on a separate piece and I struggled between how to make it work whilst still making the container look normal (eg. no big holes on the finger lip section)

I came up with a sliding system where you can add as many of these brick pattern pieces you want to the finger lip of the container. Because some of my containers can be broken down from 1 compartment up to 8 compartments.

So you would buy these small parts separately and you don't need to glue them to the containers. (which means you can change your storage system constantly)

After resizing the storage containers, I went back and looked at Volumes for each compartment and based them off the largest lego pieces I could find. 1x 16  bricks.

Here I am testing the top storage compartments 

Here I am comparing my storage volumes with the volumes from Akro Mils and a Lego Board game. It helps me to position which container/compartment compares to existing stuff. From there I try to compare pricing and to compete with the existing products on the market.

I designed the logo quite quickly. ULF - Ultimate Lego Furniture

Here I am experimenting with the logo and how it is applied to other colours and materials. I'm not really happy with it. So i might just change it completely.

Here is the latest 3D Concept. The design has evolved quite a bit. A lot of work has been done on volumes to get compartments that will fit lego in ways that I think would be appropriate for storage/sorting.

Not perfectly to scale, but a representation of how the table would work. People sitting around it and rotating the storage drawers until they get to the parts they want. Then closing the drawer so that it can be rotated for other people. 

An exploded view of the old Medium Sized container with a middle divider to give you the option to make it 2x small containers. And the 3 compartment trays up the top to give more workable storage solutions.

This Medium sized container can be split from 1 compartment up to a total of 5 compartments of different sizes.

The Large sized container can be split from 1 compartment up to a total of 8 compartments of different sizes.

The Extra Large sized container can be split from 1 compartment up to a total of 13 compartments of different sizes.

I would start off with one height for the containers, but later make another one at nearly double that height. 

But the current breakdown for parts would be  :

* Medium Container (can divide into 2 main compartments)

* Large Container (can divide into 3 main compartments)

* Extra Large Container (can divider into 5 main compartments)

* 1x Divider 

* Medium Top Tray (3 compartments)

* Large Top Tray (5 compartments)

* Extra Large Top Tray (8 compartments)

I tested how much room i needed below the top compartment tray for larger piece storage. Whilst you can't fit the biggest Lego pieces in there, you can fit a lot of things in the bottom. 

A good example would be putting Minifig shirts and pants in the bottom part and heads, hats, weapons up the top.

This is the container without any dividers or compartments.