How Does an Architect’s Design Become Buildable Millwork?
- Commercial Millwork
An architect’s design becomes buildable millwork when the fabricator turns it into shop drawings, engineers the hidden structure and connections, chooses materials that suit the space, and tests any doubtful detail with a prototype before production.
A strong architectural concept is only the beginning, because before custom millwork reaches the shop floor someone has to determine how it will stand, connect, perform and hold up over time.
On The Maker’s Intent, host Mike talks with Kyle Greenfield, president of AF Johnson Millwork Company in West Des Moines, Iowa, about how that happens while the designer’s original vision stays intact. Their conversation covers shop drawings, collaboration, structural planning, material selection and prototyping, the steps that make up AF Johnson’s design-through-installation process.
Why Can an Architectural Design Be Difficult to Build?
One of the biggest challenges is making sure a design can support itself.
Kyle explains that large features, especially tall walls or complex assemblies, may need an internal structure that is not obvious in the original design. The millwork team has to determine how individual pieces will connect, how the finished assembly will remain stable and whether additional support is needed.
That technical planning has to happen without changing the appearance the architect intended.
How Does Millwork Move From Drawings to Fabrication?
AF Johnson Millwork Company starts with the architect’s or designer’s drawings and develops millwork shop drawings that break the concept into buildable parts.
Those drawings are reviewed with the design team so questions, comments and revisions can be addressed before production. Once approved, the 2D information is developed further in CAD, where components can be prepared for CNC machining and fabrication.
The Architectural Woodwork Institute notes that shop drawings can communicate details such as construction, dimensions and attachment methods. This gives architects, contractors and fabricators a shared reference before materials are cut.
How Does Value Engineering Protect the Design?
Value engineering protects the design by changing hidden connections, supports and materials instead of the look the architect drew. It is not simply about lowering cost, and Kyle says a change can lower the price or make the piece last longer, even when the first cost is slightly higher.
Kyle says many challenges involve connections and fasteners. Visible screws or nails may interfere with the intended finish, so the team may need to develop concealed fastening or internal support methods.
When AF Johnson Millwork Company sees a potential problem, the team can bring an alternative to the designer based on methods that have worked on similar projects.
Material selection is another part of that process. A product that works well in one environment may not perform well in a high-traffic or moisture-prone space. The U.S. Forest Service explains that wood responds to changes in moisture and humidity, which makes environmental conditions an important consideration when choosing materials.
Why Is Preconstruction So Important?
Preconstruction brings together the designer, end user and millwork team before fabrication begins.
The designer understands the visual intent. The customer understands how the space needs to function. The millwork team understands fabrication, materials, installation and long-term performance.
Kyle describes the goal as getting everyone “on the exact same page.” That early communication helps the team produce something that looks right and works properly once installed.
How Can Prototypes Prevent Costly Problems?
A prototype shows the designer and end user the real size and feel of a piece before the full order is built, which a 2D drawing often cannot do.
Kyle shares an example involving ticket counters for an airport. The counters looked unusually small, so AF Johnson Millwork Company built a prototype before producing the full quantity.
When airport representatives saw it, they immediately realized the counters were too small for their needs. The design was revised before full production began.
Building one prototype helped avoid rebuilding an entire group of finished counters.
Can a Small Change Make a Design Work Better?
Yes, and sometimes a complicated problem has a relatively simple solution.
Kyle describes a curved trophy wall created for a bowling alley. The wall included curved wire doors that needed to open while keeping the intended appearance, because a bowler who rolls a 300 game gets a personalized pin placed in that wall.
The original design created a pinch point that prevented the doors from operating smoothly. AF Johnson Millwork Company suggested reversing the opening direction. That small adjustment allowed the doors to function correctly without significantly changing the overall design.
It is a good example of how fabrication experience can preserve design intent while solving practical problems that may not appear on the original drawings. Kyle tells the story in a short clip on YouTube.
Watch the Full Conversation on YouTube
Want a deeper look at how an architect’s design becomes buildable millwork? Watch the full episode of The Maker’s Intent on YouTube, or listen on Apple Podcasts. Kyle Greenfield explains how AF Johnson Millwork Company approaches shop drawings, prototypes, structural challenges, material decisions and fabrication details while helping architects turn ambitious ideas into functional finished millwork.
If a design on your next commercial project looks hard to build, talk with AF Johnson Millwork Company before the drawings are final.
Frequently Asked Questions
What Are Millwork Shop Drawings?
Shop drawings provide detailed information about dimensions, materials, components, construction and installation so the millwork can be fabricated accurately.
Why Are Shop Drawings Reviewed Before Production?
Review allows architects, designers and fabricators to confirm details, resolve questions and make changes before materials are cut.
What Is Value Engineering in Millwork?
Value engineering looks for practical ways to improve cost, durability, fabrication or installation while maintaining the intended appearance and function.
Why Might Custom Millwork Need Internal Support?
Large or unusually shaped assemblies may need framing or an internal structure to remain stable and secure.
When Is a Millwork Prototype Helpful?
Prototypes are useful when scale, ergonomics, appearance or functionality may be difficult to judge from drawings alone.
Why Does Material Selection Matter?
Materials respond differently to moisture, traffic and everyday wear. Choosing the right product for the environment can improve durability.
Can a Millwork Fabricator Recommend Design Changes?
Yes. Fabricators may suggest changes to connections, materials or construction methods when those changes improve buildability, performance or long-term use.
Mike Downer: Hello, everybody, and thanks for joining us once again on Howell’s Farm Experience. I am your host, Mike Downer, and I am here once again with Erin Conner. How are we doing today, Erin?
Erin Conner: Good. Glad to be back. It’s a gorgeous day to be out on the farm.
Mike Downer: It looks like, from that background there, you’re in a nice, air-conditioned room and just enjoying staying out of the heat.
Erin Conner: Actually, I’m in the hayloft of the barn, our antique 1910 barn, where we have all the dried flowers that we grow here. So when you say air-conditioned, I think it might be a little warmer than that.
Mike Downer: I was being a little bit of a smart aleck. I just had to give you a little bit of guff before we got started. I appreciate you taking the time, and I know it’s a little warm out there today. But look at that hayloft. I’m telling you, nobody’s hayloft is that gorgeous. For a hayloft, it’s pretty impressive.
Erin Conner: We’re Iowa’s largest dried flower hayloft. You will not see this hayloft anywhere else. We’re it. We’re the place to be if you want to see dried flowers. It’s really cool.
Mike Downer: That is really cool. I’m sure I will see that in person very soon. I’m going to let a little of this heat get away from us first.
Today, we’re going to be talking about fall and how you can make a pumpkin patch day the best day of fall. So, Erin, what should families know, bring, and plan for to have the absolute best experience at the pumpkin patch?
Erin Conner: Well, here at Howells, we’re near Des Moines, about 10 minutes from Mills Civic, and we’ve watched thousands of people come through our doors every year. There are different tips depending on the month and time of year.
If you’re visiting in September, I would suggest bringing your cute hat. Sometimes September can be a little hot, so you’re welcome to bring water bottles. If you have little kids, I suggest bringing strollers because kids get tired. They’re running from place to place, so strollers definitely help.
Of course, all the girls always want to do those cute Instagram pictures with the short shorts and crop tops. I suggest doing that in September and not in October when it’s freezing. I’ve seen people do it in October too, but if you’re going to do the summery outfit kind of photo shoots, try to do those in September instead of October.
Also, wear good footwear, like closed-toed shoes or tennis shoes that you’re okay with getting a little dirty. I don’t recommend bringing stilettos out here. There’s a lot of gravel, and you also walk on grass. You never know when you might step into a soft spot in the grass, and we don’t want that to happen to you.
Mike Downer: That makes sense. What should families wear to stay comfortable during Iowa’s unpredictable fall weather at the pumpkin patch? Give us some ideas for later in the fall when the weather can be unpredictable. What are your recommendations?
Erin Conner: The must-have for going to a pumpkin patch is wearing a flannel. You’ve got to bring a flannel. That’s the thing to do, and those are the pictures you’ve got to get: matching flannels for the whole family.
Some days, though, it’s a little too cold for flannels, so bring a hoodie. If you forget and you’re cold, we’ve got you covered. We have a gift shop full of Howells merch, including sweatshirts, hats, and gloves. If it gets a little too cold out here for you, we can hook you up.
Mike Downer: That’s awesome. Any flannels?
Erin Conner: Not yet, but that’s a good idea.
Mike Downer: You need one with a little logo. I’d buy one.
Erin Conner: Yeah, a logo flannel would be awesome. I’ll have to look into that one.
Mike Downer: Definitely. You were talking about flannels, and they’d probably sell like hotcakes.
What are the must-bring items that can make a pumpkin patch visit easier, safer, and more enjoyable? What’s on your checklist of things that people need to bring?
Erin Conner: Your camera. You definitely need to bring your camera. Strollers for kids, of course.
I would also bring an open attitude for having a fun experience on the farm because you’re going to see so many things and do so many unique things that you would never do in town. It’s going to be eye-opening how much fun you can have out here on the farm.
Mike Downer: Oh yeah, definitely. It is a different experience. It’s not like going to a mall in any way, shape, or form.
How should families plan their visit so they can enjoy the activities, food, and pumpkin picking without feeling rushed?
Erin Conner: Here at the farm, we open at 10. I recommend coming at 10, going to play, and letting the kids run off some energy first.
We also have concession stands here on the farm, and our food options are not the type of food that will break the bank. They’re very well-priced, hearty foods that we make here on the farm.
Once you get your lunch, you can go out to the corn maze and pumpkin patch, pick your pumpkin, come back, wash your pumpkin, and then go play some more.
I recommend layers because it might be chilly in the morning, and then all of a sudden, it’s 2:00 and you’re sweating bullets. Layers help a lot out here. Strollers for the kids also help because you can shove the layers inside.
Mike Downer: Good advice. I know you talk a lot about Instagram moments and everything else, so tell me a little bit about where the best photo spots are at Howells. When should families plan for the best lighting, time of day, season, and everything else?
Erin Conner: My favorite spot for fall pictures is our pumpkin wagons, which are in our yard. The best time to take those pictures is when the trees are changing and the leaves are turning colors, which is around October 10 or so.
That’s when you get the background of the leaves in your pictures, with you holding a pumpkin on top of your head and the whole wagon full of pumpkins behind you. That’s my number one favorite.
If you’re into flowers and the whole whimsical experience, the flower field is beautiful in September. With the flower picking, you can run through the fields in your dresses, smell the flowers, and enjoy the whole scene. We have a couple of photo ops out there, but the whole field itself is a photo op.
Mike Downer: Very cool. What’s your recommendation for the best time of day for lighting?
Erin Conner: Early morning at 10, or later in the afternoon around 2, 3, or 4, when the sun is at a certain angle. That way, the sun will be on your face versus behind you.
Cloudier days are better for pictures, just from a photographer’s perspective, because of the lighting. But it depends on the angle when you take pictures around the pumpkin wagons.
Mike Downer: Very cool. Just so families can pre-plan things a little bit, what parts of the Howells experience are free, and which activities require admission?
Erin Conner: When visiting the farm, we have two options. We have our farm market, which is open year-round, and there is no admission to visit the farm market. Inside the farm market, we also have a little shopping area where you can get your mums and pumpkins and visit that area. There’s no cost for that.
But if you want the pumpkin wagons, the activities, the wagon ride, the corn maze, or even if you want to go see the goats or do goat cuddling, you will need admission for that.
You have the option to either just go shopping or go to the fun farm. You can decide when you get here because there will be an option for you to go straight into the barn before you go into the fun farm area.
Mike Downer: Very cool. Since this is about how to plan your day at Howells, how can parents make a pumpkin patch visit feel extra special and memorable for the kids?
Erin Conner: To make it extra special and memorable for the kids, get in there with them. Do the activities with them. Get down on the ground with them. Help them build mud pies. Have a competition to see who builds the best mud pie.
Get in the corn pool with them and bury your kid in corn, or have your kid bury you in the corn. They will remember that way more than if you just take them to a pumpkin patch and sit there.
You’ve got to interact with the kids. You’ve got to have fun. You’ve got to be a kid yourself.
Mike Downer: Other than taking pictures, put the phones away.
Erin Conner: Exactly.
Mike Downer: What can couples or adults without kids enjoy at Howells during the fall season?
Erin Conner: The whole environment is fun for adults and couples. Come upstairs into the hayloft and buy your girlfriend or wife a flower bouquet, or have her pick out her own flower bouquet. Go out to the flower field, pick your own flowers, ride the wagon ride, get lost in the corn maze, and enjoy some food.
We also have adult beverages, depending on your age, if you want. We’re not just for little kids anymore here at the farm. We’re for all ages.
We also have a bathtub train. It’s like a bathtub, and adults can fit in it. There are activities for adults to do. It’s not all about the littles.
Mike Downer: That sounds like a great date night, actually.
Erin Conner: Yes.
Mike Downer: If I were a young man and dating a girl, I would definitely take her out there. Lots of brownie points.
Erin Conner: Absolutely.
Mike Downer: Just tell her to put on her sneakers and have a great time out there. Maybe have an adult beverage or two.
Erin Conner: One or two.
Mike Downer: Let’s wind this up. We’ve talked about all the planning, and now people have had one of the best days of their lives out there at Howells, obviously. How can families keep the pumpkin patch experience going at home after the visit?
Erin Conner: When you’re at the farm, you can buy your pumpkin and maybe pick up a little souvenir for the kids to remember the day, like a little stuffed goat. All of our stuffed goats have the pumpkin patch logo on them, so they can say, “Oh, this is the pumpkin patch goat.”
We also have stickers they can put on their water bottles in the middle of summer. They can say, “Oh, that’s my sticker I got at Howells when we picked out our pumpkin.”
You can also print out the pictures you took there or put them in a digital frame for the kids. Then they can say, “Remember that day, Mom, when we went to the pumpkin patch?” It’s the little things.
Maybe even buy a plant and put the kid in charge of taking care of it.
Mike Downer: Responsibility. Yep.
Erin Conner: Then that way, it’s their plant that they got at Howells, and it could last for years.
Mike Downer: That’s one of those things where maybe 20 years from now, they bring their own kid back and say, “I remember when Grandma and Grandpa took me to Howells, and I planted this. It was only this big, and now it’s huge.”
Erin Conner: Exactly.
Mike Downer: All right, Erin. Thank you so much. I think everybody now knows what they need to know when they’re planning their trip out there: comfortable shoes, knowing you might get a little dusty and a little dirty, but that’s part of the fun.
Just get there early, plan for a big day so you don’t feel rushed, and get yourself a couple of plants while you’re out there to make that experience last forever. Does that about sum it up?
Erin Conner: That’s perfect. That’s great.
Mike Downer: Awesome. Maybe I should do your TV commercials for you.
Erin Conner: I’ll step on that.
Mike Downer: Sounds good. I’m free, so you can just use me.
Thank you so much, Erin. I always enjoy talking to you. Get into some air conditioning because I know that beautiful loft is a little bit warm.
Erin Conner: It sure is today.
Mike Downer: All right. Thanks again, Erin, and we’ll talk soon.
Erin Conner: All right. Thank you.