Design #4:

Tackling a Problem

While most of our products are furniture, we felt a less expensive wood product of some kind would be more successful at markets and events. As someone passionate about music on vinyl, I already had ideas about what a Wood Lab record crate could look like.

The Record Collector’s Burden

While records are exceptionally thin (2-3mm) and can therefore be stored very efficiently, their awkward dimensions, fragile nature and high density makes storage and movement difficult. It’s challenging to carry more than 10 or so records in your hands, beyond which your best bet is lugging the whole crate you’re using to store the records. For those with records stored in a cabinet, the crate isn’t even a viable option.

On top of this, the small number of products designed for moving records all enclose them in a case, making them inconvenient to access and impossible to display.

My first crate design could hold about 70 records, was stackable, and could be carried in one hand. It met the criteria that it could be constructed quickly out of a single piece of material. I finished the prototype the day we bought the wood.

The design was, however, deeply flawed. For its footprint, the number of records it held was miniscule. Additionally, it was far too heavy, making single-handed carrying difficult - even painful. This was due to excessive material needed to make the crate stackable, despite my effort to limit the amount of materials used. In addition, the nature of its stackability made the sides taller than the records themselves, making it less than optimal for accessing or displaying whatever it was storing. While it would mean compromising on storage capacity, I opted to focus the next iteration on carrying comfort and display capability.

Above: My records, example of existing carry case design.
BL: Original Crate CAD, Original Crate Prototype

Iteration 2 and 3: The Offset Handle

Using what I had learned about how records fit and move in a crate from the first design, I completely reworked my design to be less of a crate, and more of a carrier. Starting with a 15° handle offset, I made a prototype using scrap material and leftover wood from the older design. Its handle was a simple slat of wood, despite my design calling for a more substantial handle design.

This one prototype showed promise in the design, but the handle offset was too extreme, and the handle itself was still uncomfortable. All future carriers feature a 10° offset, as well as handles resembling my CAD drawing.

Left to Right: CAD of Iteration 2, Prototype 2

Above: Prototypes 2 and 3

Below: Prototype 3 with 30 records

Further Refinement

Once we had settled on dimensions and design, our next step was to make the product more refined and market ready. We did this with a couple of key changes:

  • All record crates sold will be made of a single wood: cherry hardwood.

  • All stapled components will be attached with countersunk, black screws.

  • The carrier may be purchased fully assembled, but can be broken down for shipment with directions for user assembly.

  • The edges of any pieces contacting the records will be given a slight chamfer.

After developing the instructional materials for assembly, we posted the product on Etsy, and began selling them in-person at markets.

User assembly instruction packet, included with every carrier.

Above: The refined assembly process allows the handle to be removed.
Below: Record carrier staged with other products.