Once we have an idea for a new or custom item, the first step is to create a 3-D computer model from a sketch or drawing. Working with the 3-D model, we can see what the finished product will look like, and we can plan out its construction. This allows us to design and engineer the product simultaneously. This process is known as "working in virtual reality". From this computer model, we can generate any necessary patterns, blueprints, and measurements. The design (left) and the main pattern (right) are shown below.     Next, the patterns are traced onto plywood or OSB (Organized Strand Board) and cardboard tubing (concrete form tubing). Once the parts are ready, assembly begins. Carpet is cut and attached in stages. During this phase, we are also connecting the parts of the structure, using a drill and screws. The front of the condo is attached to the sides, while these parts are covered with carpet (right). Meanwhile, the back panel has been carpeted, as well (left). The reason for the gaps in the carpet is so that the two interior floors can be attached snugly to the front and back panel. Once again, a drill and screws are used.     At this point, the main section has been carpeted and assembled (left). Now, the two tubes must be carpeted, inside and out (right). This is done with two pieces of carpet. The first piece will cover the inner surface and wrap through the opening. The second piece will cover the outside and be wrapped around the edges to the inner surface. Normally, the opening is wrapped inward; but this condo design is unique.     Lastly, the carpeted tubes are attached. Although designs differ from one product to the next, the process used to build them is basically the same. Although this item does not include decorative carpet inlays, they are available as an option on any of our products.  Click to see how carpet inlays are made.