Few things can have as powerful an effect on the feel and function of a space as a well designed and well crafted built-in. The ability of a painted wall unit or bookcase to transform a space is remarkable. We should know, we’ve been taking our own before and after photos for over ten years now. We’ve also been refining our use of select materials, finishes, and processes to create the finest work possible.

Our Materials

We’ve found that, most often, the best material for constructing our cabinet and door frames and other solid wood parts is soft maple. Despite it’s name, soft maple is considerably harder than pine or poplar. This means it is much less likely to suffer dents and dings. It is also quite resistent to warping and twisting and is remarkably smooth, providing an excellent surface upon which to apply paint.  Large panels are often best made from MDF(read more about MDF and other panel materials we use here), which is immune to the cracking and splitting that can occur within large areas of solid wood as a result of seasonal changes in humidity.  Using MDF allows us to construct a stronger cabinet component that will last longer and look better over time compared to solid wood.

Finishing At It’s Finest

The quality of the painted finish is a major part of a successful built-in cabinetry project.  Working in our dedicated finishing area, we create a high quality and extremely durable finish by employing a labor intensive process involving multiple stages of priming and sanding, followed by several coats of Benjamin Moore’s Aura Satin Enamel.  Aura is a premium water-based finish that provides a lustrous feel. It is a remarkable paint, similar to a quality oil based enamel, but eco-friendly and non yellowing.

A Note On Pricing

There is a widely held notion that painted cabinetry is a less expensive option than many natural wood finishes.  While this may have been the rule at one time, it no longer holds true.  There are many functional and attractive natural woods that can be used for built-in projects at a lower overall cost than a painted finish.  There are also many exquisite woods that can be used for built-in projects at a cost considerably higher than a painted finish. The reason for this is simple: labor.  The single largest component in the cost of a project is the labor of the skilled craftsmen we employ to construct and finish each piece.  And while the cost of paint grade materials may be slightly less than some furniture grade species we’d recommend for a clear finish, the difference is more than offset by the added cost of the labor required to produce a long lasting and beautiful painted finish.  We believe this is a good thing, in that allows us to offer a wide range of options to fit every budget while encouraging the selection of materials and finishes based not on cost, but on design considerations.

Making It Happen

From concept and design, to fabrication and installation, the Hat Factory team possesses the knowledge and skill that will make your painted built-in cabinetry project a success.  For more information, or to discuss your project, give us a call at 914.788.6288.

This dining room wall-unit was a fun project.  The before and after photos are a great illustration of how to successfully resolve a couple of common design issues that we encounter on a regular basis.  As you can see in the before photo (below), an existing structural bump-out in the right hand corner makes it difficult to place a piece of furniture against the back wall and contributes to the space feeling smaller than it really is.  The existing sideboard cabinet, pushed all the way to the left side, ends up calling more attention to the problem than it does to fix it.   Our solution was to replace the free standing cabinet with a wall to wall built-in that defines a consistent plane across the room.  In addition to providing a centered focal point,  it also offers increased storage and a more open, larger sense of space.

Another topic from the list of questions we get asked a lot is what type of wood should I choose for my project?  This can seem like a daunting task, and one not to be taken lightly. After all, the entire success of a project can be jeopardized with the wrong choice of material. Fortunately, there are many great woods to choose from, and by evaluating some basic criteria it can become an easy and risk free decision to pick the right one. The criteria we use include, but are not limited to, the following:

• Cost
• Availability
• Durability
• Tone
• Texture
• Special Considerations

I’ll discuss cost, availability, and durability here and come back to the more subjective issues of tone and texture in later posts.

Cost & Availablity

There are many high quality woods that are suitable for the making of quality furniture and cabinetry.  Some of the most popular that come to mind are ash, maple, oak, cherry, mahogany, and walnut.  These are all readily available, stable, and highly attractive woods that are ideal for most interior woodworking projects.  And, while costs do vary from species to species and exceptions must be made for highly figured and prized boards, this core group of materials is available at reasonable cost. In fact, because such a large percentage of the cost of any custom furniture or cabinetry project is the labor of the skilled craftsmen creating the piece, the cost of the material is rarely the determining factor in choosing a material.  This is actually good news because it means that we can focus on choosing our material based on appearance, not on price.

Durabilty

While traditionally divided into categories of  hardwoods and softwoods, these lumber classifications have more to do with the cell structure of how a particular species than they do with the strength of toughness of a particular wood and offer little practical advice on what might be an appropriate material for a given project.  In truth, almost all hardwoods and mahoganies are suitable for furniture construction. While special consideration may be given to particularly durable woods, such as maple or oak, for projects that will be subject to extra abuse, all of our standard hardwoods will hold up just fine.

Tone & Texture

Next time we’ll discuss “tone & texture,” which are the terms we use here in the shop to define the color and appearance of a particular wood.   These are the most important criteria in selecting a material for each project, and our unique approach ensures we can help you pick the perfect material for yours.

We are pleased to announce that we have added the F.W. Honerkamp Co. to our stable of “green” suppliers.  Jeff Honerkamp, part of the 4th generation to work in the family lumber business, has taken the lead in offering an extensive line of FSC certified panel products.  He is extremely knowledgeable about all aspects of green building materials as well as LEEDS architectural requirements.  We look forward to working with him and the Honerkamp team as we continue to offer our clients healthy, sustainable furniture and cabinetry of the highest quality.

Exciting New Products From Honerkamp

• Arreis SDF – Sustainable MDF
• FSC Certified Hardwood Lumber
• SkyPly – No added formaldahyde veneer core plywood
• Shinnoki – ready to use European veneered panels

Some of these items are newer, green versions of tried and true staples of the cabinetmaker’s craft. Others are new and exciting products that open up fresh design possibilities and just happen to feature recycled content and low VOC adhesives.  As we get our hands on some of these newer items, I’ll share our experiences with them here on the blog.

No, we are not going to start selling iPods made of wood, and the list of things we have in common with Steve Jobs is quite short. (I, for one, never wear turtle necks.) But one of the keys to the success of Apple’s products and software is how focused they are on the user experience during the design process.  I imagine it’s very similar to what we do here as we work through the design of a piece of furniture or a cabinetry installation.  By paying close attention to the details of usability and function, we work to ensure that not only will the project succeed visually, but purposefully as well.

Put another way, the emphasis placed on what to build is equally important to the craftsmanship of building the object itself.

One question that I get asked a lot is “what are your cabinets made out of?” It’s an easy question, but a hard one to give a good answer to if you don’t know why the customer is asking.  So, I thought I’d offer some information here about the materials we use most often,  why we use them, and why we stay away from others.

In future posts I’ll discuss some of the hardwoods we use and highlight some of the places where we source huge slabs, but I thought I’d get started with the manufactured products since they seem to be least understood.

Plywood

Plywood is the workhorse of custom cabinetry. A manufactured board made up of several layers, or plies of wood glued together to form a panel, plywood is strong, lightweight, and stable. Cabinet grade plywood is the perfect material for building the sides, backs, and bottoms of cabinets. Available in a range of thicknesses, plywood is often referred to by the type of wood used in it’s outermost plies.  Cherry plywood, for example will have cherry veneer as it’s outer surfaces.  The interior surfaces will be of a secondary wood, often spruce or alder.

Veneer

I’ll just say it.  Veneer is not a bad thing.  Some of the most stunning, highest quality furniture could not be made without it. Real veneer is very thinly sliced wood that is intended to be glued to a substrate such as a secondary wood,  plywood or an MDF panel.  There are many situations where veneer is a more desirable choice than solid wood. Once glued to an appropriate substrate, veneer is more stable and less susceptible to movement caused by changes in humidity.  In addition, veneer allows for exceptional control of both the color and grain of the finished project as well as the possibility to create a range of visual patterns that cannot be achieved any other way. (Think Art Deco. Think Modern.) If used correctly, there is very little chance that the veneer will chip, crack, or separate from it’s backing.

MDF

Short for Medium Density Fiberboard, MDF is an engineered wood panel made up of a mixture wood fibers and resins formed by applying heat and pressure.  MDF is a high quality product with characteristics that make it desirable for cabinet and furniture construction. It should not be confused with particleboard. Particleboard is awful stuff.  Smoother and even more stable than plywood, MDF is an excellent choice as a substrate for veneer or used for panels that are to be lacquered or painted.  Because of it’s extremely uniform surface, MDF is not prone to “telegraphing”. Telegraphing, which most often occurs with lower quality plywood or extremely thin veneers, is when the grain of the substrate can be seen or felt through the top surface.  Available in water resistant varieties that contain recycled materials and formaldehyde  free resins, MDF is a great green option and suitable for furniture, and kitchen and bathroom cabinetry.

Beds are always a fun project for us, so I thought I’d show one off as a recently completed project on the blog this week.  Crafted of rift white oak with an ebonized finish, this modern style platform bed has 6 big storage drawers and is built tough enough to handle jumping monkeys (or kids, in case you don’t happen to have any monkeys ).

The headboard features a 3 panel design.

Assembly starts with the legs and center rail which act as a spine.

The completed bed, prior to finishing.

A close-up of the finished bed, showing one of the storage drawers.

The completed bed with the support slats installed, ready for a mattress.

There is a lot of talk these days about all things green. Organic, hybrid, recycled – just a few of the buzz words associated with making things better for us and better for the environment. As designers and furniture makers, we’ve got our own list of buzz words – sustainable, low VOC, formaldehyde- free. But what do all these terms mean? And what are the practical applications when designing and building furniture and cabinetry for ourselves and our clients?

As they pertain to furniture and cabinet making, the terms Green and Eco-Friendly are often used interchangeably. In practice, the issues they represent are two-fold. Whether referred to as “green” or “eco-friendly,” what we are really discussing are the separate matters of environmental sustainability and the assurance of healthy homes. In order to make informed “green” decisions in the design and production of furniture and cabinetry it is important to understand both these issues.

Sustainability

Sustainability is the idea that the materials being used are harvested and/or manufactured in an environmentally responsible way. For hardwood lumber and mahogany this means using logs that are felled in forests managed to protect wildlife habitats and soil erosion. This often includes bans on destructive techniques such as clear cutting. There are programs that award certification to companies that harvest lumber according to a strict set of guidelines. The Forrest Stewardship Council (FSC) is one. The Sustainable Forestry Initiative® (SFI®) is another. As we purchase lumber from our suppliers, Hat Factory Furniture looks to ensure that we are provided with material that meets these guidelines.

For manufactured panels, such as plywood, MDF, and newer entries like Wheatboard, sustainability is achieved by using as much recycled content as possible and using replenish-able, non traditional materials such as natural grasses.

Bamboo is receiving a lot of attention lately as a sustainable product. Because it grows so rapidly, bamboo can be harvested rather aggressively without much concern of depleting stocks. It is then processed into a wide range of manufactured panel products that can be used for the construction of cabinetry and furniture. The appearance of a bamboo panel is distinct and quite striking and can be used to dramatic effect in a design. For this reason alone, we often incorporate bamboo with other materials within a project.

Healthy Homes

The second aspect of being “green” with respect to furniture and cabinetry design is concerned with creating a healthy environment within our workplace here at the Hat Factory and in the homes and offices of our clients. This involves selecting and using materials that limit the release of harmful fumes and emissions.

All forms of manufactured panels used in furniture and cabinetmaking, such as plywood, MDF, and particleboard are essentially some combination of wood, wood dust, and glue. Traditionally, these glues have included Formaldehyde, a toxic chemical compound found to be both allergenic and carcinogenic. In response to customer demand and tighter restrictions, many manufacturers have started producing panels that do not contain formaldehyde resins. Because these newer panel products are often made with recycled wood fibers and waste material, they are a key component of environmentally responsible cabinetry construction.

The final area of focus to maintaining a healthy environment is concerned with the selection of finishing materials. Many traditional wood finishes, such as varnish and oils contain high levels of volatile organic compounds (VOC’s) and heavy metal compounds that are employed to help finishes dry more quickly. These toxic elements continue to release harmful pollutants long after the initial drying and curing of the finishes. More and more “green” finishes are being developed that avoid the use of these substances. At the Hat Factory, we are experienced in selecting and using a wide range of environmentally responsible finishes. These include water-based lacquers, paints and stains that can provide beautiful, long lasting results while contributing to a healthy workplace, home and planet.

Today, the options for creating environmentally responsible furniture and cabinetry projects are great and continue to expand. The importance of being educated in the products and techniques that enable green construction is key. Here at the Hat Factory, we are committed to pursuing that knowledge and using it to the benefit of our clients. Good design, high quality, and eco-friendly.

I’m often asked to compare how a Hat Factory Kitchen stacks up against cabinetry purchased from a kitchen cabinetry showroom. The basics are easy;  we offer great design and space planning advice; we provide superbly crafted, high quality cabinetry at a fair price; we offer all the same nifty storage features and self-closing drawers. But how to explain the big difference? The one that gets lost in the jumble of “Custom vs. “Semi-custom” and whatever other phrases the big manufacturers are tossing around?  To explain that one, I just tell people how buying cabinetry from a showroom is like shopping for pants at The Gap.

You need pants. So you head to The Gap where you find, on display, several different styles of pants.  Each style comes in a couple of different colors and a range of sizes. With any luck, you’ll find a style that you like in a color that matches your shirt in a size that fits and doesn’t make your butt look big.  And that is exactly what you’ll find at a cabinetry showroom: a couple of different styles, each available in a couple of colors, and a range of sizes that (hopefully) can be configured into a workable layout to fit your space and your needs. Easy enough to do if you’re a perfect size 6, or your kitchen is exactly 11 feet, 2 inches long with no doors and no windows.  Slightly harder in the real world.

Here at The Hat Factory, we take a different approach.  We take the time to sit down with you to learn about your style, your space, and how you use your kitchen.  Maybe you’re a baker, or have a big family and lots of company. Maybe you need rows of open shelving to display your Fiestaware.  Maybe you’ve got a small space with odd little nooks. Not a problem.  We’ll come up with a plan that combines a great work flow with plenty of storage and a look that ties it all into your home. From initial concepts and planning to installing the knobs, we’re with you every step of the way in creating the perfect kitchen for you.

It often seems to me that there is a perceived chasm between design and craftsmanship. As if the talent of a designer and the skill of a craftsman must never mix.  Nothing could be further from the truth.  Good design benefits from the knowledge of skilled craftsmen. Quality craftsmanship is improved with quality design. That’s the unified approach we apply to all our projects here at The Hat Factory. It’s what we do.

For the client, the benefits of this design/build approach are many. Prime among them is the expansion of possibilities. By working seamlessly across the boundaries of the design process and fabrication, we are able to create both simple, effective solutions to complex design challenges and stunning visual details.

Equally important to our clients, and perhaps an even bigger benefit of the design/build approach is the ability to control costs across the entire project.  Frequently, a small change to a single detail can result in a substantial cost savings.  By approaching a design project with a clear view and understanding of the fabrication challenges that may be present, our team is able to find the most cost effective way to provide the best possible result.

Ten years later, our mission here at Hat Factory Furniture hasn’t changed.  We continue to unite the disciplines of design and craftsmanship, providing our clients with the finest furniture and cabinetry possible.