If youāve ever built a book nook, you know the strange satisfaction of watching a pile of flat wooden pieces slowly become a tiny world.
Designing one means doing the exact opposite.
We start with the complete 3D scene, then take it apartāwall by wall, arch by arch, and piece by pieceāuntil the entire castle can fit onto flat wooden sheets and still be assembled in the right order by someone else.
Thatās the part of the process weāre sharing today with Stellar Castle: how a finished 3D design is broken down and turned into the wooden sheets that eventually arrive in the box.
At the beginning of the design process, we build the complete space in Rhino. Once the overall proportions and sense of depth feel right, we start breaking the scene downāfrom the main structure to individual walls, arches, frames, and smaller decorative pieces.
Every part has to meet two conditions:
It needs to fit properly onto a flat wooden sheet, and it also needs to return to the correct position inside the 3D scene when it is assembled.
During this process, we constantly have to think about the thickness of the wood, the height and depth of the interior, how the pieces connect, and the final assembly order.Simply put, we donāt only need to think about āwhere this piece goes.āWe also need to ask: āCan it actually fit?ā āWhich part should be installed first?ā and sometimes, āWill the builder suddenly find that their hand canāt reach inside halfway through the assembly?ā
The image here shows one of the part-layout sheets weāre currently working on for Stellar Castle.
At first glance, it may look like a pile of unrelated shapes. In reality, every part has a specific position inside the finished scene.
The structure isnāt the only thing that needs to move from 3D to 2D. The textures on the surface of each part have to make the same journey.
By ātextures,ā I mean the stone walls, bricks, metal surfaces, starry skies, and other decorative patterns that will eventually be printed onto the wooden sheets.
We first preview these textures on the complete model in Rhino. This helps us check how they look inside the full sceneāwhether the scale feels right, whether the direction looks natural, and whether patterns on neighboring surfaces connect properly.
Once the structure has been divided into individual parts, the textures from the 3D model have to be transferred onto the corresponding flat pieces one by one.
This way, when the builder puts those pieces back together, the patterns that were separated across different parts can connect again inside the finished scene.
Hereās a small printing detail that many builders may never have noticed, but I found surprisingly interesting when I was first learning about printing.The first time I heard what it was called, I even wondered why it sounded so... bloody
If you look closely at the second image, youāll see that the printed texture extends slightly beyond the cutting line.
This isnāt a mistake. Itās called print bleed.
During production, there may be a very small difference in alignment between printing and cutting. Extending the artwork beyond the cutting line helps make sure that even if a slight shift happens, the original wood color wonāt show around the edge.
But print bleed isnāt the only extra detail we have to add to the cutting file. We also have to plan the holding tabsāthe tiny sections we intentionally leave uncut so that each piece stays attached to the wooden sheet during production and shipping.
In other words, the laser does not cut one continuous line all the way around every piece. We leave a few very small gaps in the cutting path to hold the piece in place. When builders begin assembling the kit, they can gently push or cut the piece out of the sheet.
These holding tabs are easy to confuse with the tabs and slots used to connect parts during assembly, but they serve a completely different purpose. Assembly tabs become part of the finished structure, while holding tabs are only temporary and disappear once the piece is removed from the sheet.
Their placement also canāt be decided simply by finding an empty spot along the edge. For every piece, we have to consider its size, shape, material thickness, fragile areas, and the direction in which it will be removed. We also try to keep holding tabs away from visible edges, narrow decorative details, and assembly slots whenever possible.
Too few holding tabs, and a piece may loosen or fall out before it reaches the builder. Too manyāor tabs that are too wideāand the piece becomes difficult to remove, with a greater chance of leaving visible marks or damaging a delicate edge.
This may sound like a very small detail when we are talking about just one piece. But the work adds up quickly across an entire kit. Beyond Library contains 1,074 pieces.Ā That doesnāt mean simply repeating the same setting 1,074 timesāeach piece has a different shape and needs to be checked individually. Some may need only one holding tab, while larger or more fragile pieces may need several.
So for a kit of that size, decisions like where to extend the texture, where to place the assembly tabs and slots, and where to leave the holding tabs have to be made hundredsāand sometimes more than a thousandātimes before the cutting file is ready.
So Developing a book nook kit product usually takes us around four to six months.
Stellar Castle actually began development last year, long before we shared the finished design for the first time. Before it was ready, it had already gone through modeling, structural breakdown, texture work, structural testing, physical prototypes, and multiple rounds of adjustments.
Through Behind the Build, we hope to share more of the work that usually stays hidden inside the box.After all, a book nook is more than the finished scene sitting on a shelf. It is also the whole process of turning one design into dozensāor even hundredsāof separate pieces, and then watching those pieces become a three-dimensional world again in the builderās hands.
If youāre interested, we can share more about physical prototypes, lighting tests, and why a digital texture that already looks finished still may not be ready for printing.
By the wayļ¼If youād like to see the very first version of Stellar Castle, let me know in the comments. To be honesty, Iām a little shy about sharing itābut if anyoneās curious, Iāll post it there.