Simple living, considered design.

My contribution was making sure the early product(s) could be produced with that same clarity: tight tolerances, smart joining, reliable hardware, and a manufacturing flow that wouldn’t collapse under real-world demand.

The challenge

Early-stage product brands hit the same wall: prototypes are “done”… but production is fragile. Plyroom needed to maintain its minimalist, quality-first philosophy while solving the unsexy realities:

• sourcing consistent hardware and finishes

• reducing assembly pain and error rates

• creating jigs/templates so parts came off the CNC accurately every time

• ensuring packing/delivery didn’t destroy the experience

My role

I handled DFM and production enablement with end-to-end translation of the design into manufacturable parts and joinery logic, sourcing and validating hardware, building jigs and templates for accuracy and repeatability, supporting CNC workflows, and setting up practical assembly and QC steps to get early runs out the door.

What we delivered

Manufacturability

• DFM review: joinery, tolerances, fastening strategy, material reality

• Part rationalisation (reduce unique parts / simplify machining)

• Assembly sequence improvements (less fiddly, less error-prone)

Production system

• Jig + fixture set for repeatable machining/assembly

• CNC-ready workflow support (tooling assumptions, nesting, repeatability)

• QA checks at key steps (before it becomes expensive to fix)

Supply chain + rollout

• Hardware sourcing, supplier coordination

• BOM / procurement notes (even if lightweight)

• Early-run delivery support (packaging logic + handling realities)

Scale

$50K development program, 2-month program
Comprehensive product library
Nationwide distribution 

Credits

Manufacturing and delivery support by Thom Luke / Threshold Design, in collaboration with Plyroom team and local suppliers.