In this video, I will show my version of recycling sheet metal scraps. This idea arose in order to reduce the cost of production of some products, the production of which left a large amount of metal waste. Everyone evaluates the expediency of this method for himself based on his own realities. From my personal experience, this niche of handmade metal furniture is quite small, but such products sell well.
I started by making a 3d model in blender, unwrapped them in Pepakura designer, based on the size of the scraps that I had. This base measures 420mm high x 480mm wide x 480mm deep (16″ H x 18.8″ W x 18.8″ D). Made from scraps of sheet metal with a thickness of 1-3mm (1/25″-3/32″). The bottom support plate is 4 mm thick and measures 450x450mm (17.7″x17.7″). Please note that I used a 600 mm (23.6″) tabletop, so if you plan to use a larger tabletop, the baseplate needs to be increased.
After I printed out the details of our future coffee base, I transferred them to metal and cut them out with an ordinary grinder. Of course, if you have the ability to cut parts on a CNC machine, this will significantly reduce the cost and time of manufacturing this base. I also want to note that when using laser cutting, you get the opportunity to make half-cuts, which will allow you to assemble the base from literally several parts. This will greatly reduce the amount of welding and post-processing.
After the parts were cut, chamfer the edges, made half-cuts and began to bend the parts. Quite a tricky stage, I started from the bottom up, docking each next detail with the previous one.
After the parts were bent, I assembled them on tacks, checked once again that they fit together, welded them completely and cleaned them. To clean the welds, I used a flap disk.
Now I began to assemble our base from the previously welded elements. I also assembled everything on tacks, in some places I had to cut, bend, etc. But since such a rough and rustic style forgives bumps and will play in our favor.
It is also a rather tricky stage of welding cactus branches, since during the assembly process the overall dimensions could shift, it is important to check that the top points of the cactus branches are at the same height. Because they will later be attached to the countertop. And if one of them is higher or lower, the countertop will not stand straight.
When the frame of our base was fully assembled, I began to weld the entire structure and cleaned all the seams.
Welded the lower support of our metal base. Then turned the base upside down and began to weld the mounting plates for fastening the table-top.
At this stage, it is important to have a flat, leveled surface of the workbench. In this case, it is enough to put the level on the lower support (the base is upside down) and set everything to be even. In my case, one branch was about 4 mm lower, I just put a metal plate of the same thickness and welded it.
After everything is ready, we begin the process of preparing for painting our cactus metal table base. Depending on what you want to get in the end and how the production process went, we apply or do not apply putty. I used an automotive, two-component, aluminum-filled putty.
After sanding, you can proceed to painting. Because I wanted an aged look for the base, I used a white primer. After polymerization, applied 2 coats of green paint. After drying, using P240 grit sandpaper, I rubbed the paint along the ends and edges and some other places of the base to create an antique effect (distressed look).
Since in some places I rubbed the paint all the way to the metal, in order to protect against corrosion, I applied two coats of clear varnish. After drying, I glued felt pads to avoid scratching the floor.
This completes the creation of our cactus-shaped metal coffee table base from scrap pieces left over from your other projects. A fun project for the weekend. Absolutely customizable & artistic metal cactus coffee table base. It will take several days of unhurried work to make.

I made a detailed DIY guide with a 3d model and a layout of parts here
https://www.instructables.com/Metal-C...

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