Proposal:
This Breakfast Restaurant Franchiser asked us if we could create a custom cloud in the shape of an egg for the breakfast restaurants. They chose our "Pearl" color for the acoustic felt. They sent over the dimensions below.
A few of the clouds had holes for lights to go through.
Challenges:
- Designing the 4'x6' cloud out of one piece of 1/2" thick acoustic felt, would have excessive sagging and bowing.
- Using 2 full layers of felt would have solved that issue, but would have not been cost effective, and was not the desired look.
Solution:
- We manufactured a support system out of felt, to be installed on the back of the cloud that followed the edge profile of the cloud, but was slightly recessed from the edge. It was recessed so it wouldn't be easily seen from the ground.
- The ring support would be between 4" and 6" wide.
- This ring of felt would reduce the overall cloud sag to about 1/8".
- We then sent shop drawing for approval (below).
- We did make a few changes to the ring on the final product to further reduce the sag.
- The finished product is very similar to our Donut Clouds
