Classical Spiral Staircase Mock-up for Manhattan Private Residence 

This project was a high-priority, fast-turnaround mock-up of the entry section for a custom spiral staircase. The mock-up, constructed primarily from laminated hardwood and plywood, focused on defining the initial three steps, the radius tread design, and the complex volute and newel post details.

Lacking a traditional lathe in our shop, the challenging, spherical newel post and the curved volute railing section required a combination of creative fixturing and advanced 5-axis CNC programming. I developed a multi-stage machining process, utilizing custom jigs to flip and reposition the workpieces, allowing the CNC to accurately sculpt the classical turning details typically reserved for a lathe. To drastically reduce mill times and optimize material usage across the entire project, I also designed and created custom MDF stock specifically dimensioned for the final components. This innovative approach not only met the tight deadline but successfully demonstrated the design's structural integrity and aesthetic precision before committing to the final, full-scale build, all while ensuring maximum fabrication efficiency.