FREE Shipping on orders over $250!
The Craft Crate Process: The 5 Steps We
Follow To Create Our New Activities
The process of creating new designs is lengthy but extremely rewarding. Here are the 5 steps we follow each time we create a new activity.
Step 1: Research
The process of creating exciting new designs centres around the interests of children. We love to engage children regarding their new interests and hobbies and encourage these by creating products catered to their needs. Here at Craft Crate, our first step is to ask children at our own centre what their interests are and what they would enjoy making. From their suggestions, we ask children at other centres whether they like these ideas, or if there are others they find more appealing. If there is overwhelming support for a particular idea, then we proceed to the design process. If not, we incorporate online research such as scrolling through Pinterest pages and discovering current trends that might peak the interest of children in an OSHC/OOSH environment. We also get so many incredible suggestions from Coordinators and Educators in the industry!
Step 2: Design
Once an idea is selected to be brought to life, Brad, Co-Founder and Chief Design Master uses CAD (computer aided design) software to create a framework for the product. He begins by designing rough shapes that eventuate in a final image. He then proceeds to design each piece individually and adds intricate detail so the grooves of each piece slot perfectly into one another. Using radiata pine can be tricky, because the properties of the wood only allow for a small degree of flexibility. After he is satisfied with each piece and the overall design, he adds intricate details and etches that bring the design to life, before the rigorous testing process.
Step 3: Testing
Testing is the most important step. At Craft Crate we pride ourselves on designing a product that is as close to perfect as we can create. It begins with a single sample which is cut using our laser cutter, more fondly known as Betty. We then make the product and check if all the pieces slide into each other.
Often, changes are required to ensure once each piece slides in, they do not come out too easily. Other improvements such as balance and stability are also monitored, as seen with our basketball hoop design. Alterations were needed as the initial design was unstable and continuously fell forward.
Using his CAD software, Brad fixed this issue, however, we noticed the rim was now too small which made scoring with a ping pong ball extremely difficult. Another alteration was made, resulting in lengthened supports for the base which created maximum stability and also used more of the sample sheet, reducing the amount of offcuts which would be otherwise wasted.
A fun fact discovered during our research was that a basketball hoop is exactly twice the diameter of a basketball. Unfortunately these measurements were not feasible due to the size of our design, however following these iterations and like all our products, we aimed to be as perfect as possible.
Step 4: Production
Once a design passes the testing stage, it is produced on a much larger scale. A sheet of radiata pine (1200mm x 800mm) is placed on the laser cutter which is synced to Brad’s software. Brad selects a file on his computer and copies multiple designs onto the sheet of wood. Each file has parts that need to be cut and others that merely require engravings to add authenticity and detail.
In order to cut through the sheet, the laser vaporises the wood, a thermal process that turns the solid into gas. The power is reduced when engraving so the laser simply marks the wood. A full cut can take up to an hour however varies according to the intricacies of the design. Once the machine finishes cutting, we inspect the final outcome and then repeat the process.
Step 5: Launching The Product
Once our designs have been cut, they are sorted into orders and sample boxes to be shipped across the country. New products are released at the start of each school term and we gather feedback from our OSHC/OOSH community and make necessary adjustments for future orders. All our products are available to purchase on our website for years to come. This process is repeated every term as we make new and innovative craft activities based on the evolving ideas and interests of the children.
Join The Family!