Our team carefully reviewed the existing Cayo products and developed a series of recommendations that would retain the key design features Coast had developed but productionise it and improve the materials and processes behind the design.

A successful design company already it was considered important to also approach the design with the Coast philosophy in mind; which is quality of materials and attention to detail. Materials selected had to be proven durable to ensure no potential for failure during use.

The design demanded the use of timber with its large sections, so a sustainable replacement was sought. The team settled on Finger Jointed and Preservative Treated and Primed New Zealand Pine. The timber is FSC accredited, and had a proven performance profile for the application.

A water based enamel was developed with Resene to form a hard durable surface that would weather very effectively. Reducing refinishing time substantially over normal stained and oiled settings.

The selection of a light colour was to effectively reflect light extending surface life.

Cushions used Dripore and Sunbrella fabrics to align with the existing coast products and to deliver the 5 years required fabric performance.

A critical part of the design process required the whole product to be knock down, this required careful redesign with the available timber sections to ensure the range stayed within conventional supplier specifications. The fasteners were all stainless to stick with Coasts design and material aesthetic. A limited number of sub assemblies and parts were developed to enable easy assembly, but efficient packaging for export.