Case Example: Design Out Waste in Plywood by Goodweather

Design consultant Goodweather explored how to maximize use of a commonly used material in staged environments: plywood sheets. A durable material that could be used over and over, the need for purchasing new plywood is often a result of designs that generate waste and offcuts. 

Goodweather recommended limiting cuts to each sheet in 1/2″, 1/4″, 1’8″, etc. Goodweather then designed a series of modular walls, risers, and bases by mixing and matching these simple shapes. 

For these design-for-disassembly template patterns visit our Resources & Inspiration page. 

Design Out Waste: Guidelines

  1. Use a whole sheet/piece whenever possible.
  2. When not possible—use division of: 1/2 sheet; 1/4 sheet; 1/8th, 1/16th.
  3. Avoid curved shares (unless you can use the waste off-cuts).
  4. Use convenient and widely available de-mountable joinery – to allow for material reuse with minimal damage.
Minimizing off-cuts in plywood sheets. Designing out waste – Rules and template designs. Design by Goodweather