> fasteners simply pull themselves out of the soft particle board, because the board itself is weaker than the fastener
This is true for most furniture. High-quality solid wood is also weaker than a metal fastener.
I do have a couple of short shelves that I got used and moved 3-4 times that look to be screwed into the material (my memory isn't that great :/) and I'm guessing at one point had a nailed on back. I'm fairly sure it just worked for me to disassemble and reassemble without change and they are somehow stable without any cross bracing. The previous owner might have changed the screws.
I also have a pair of IKEA chairs that were quite unstable when I got them used and the issue turned out to be that the order of tightening screws made a huge difference. Luckily it was new enough that it was easy to find the manual on IKEA's site or I would never have figured it out. I think a number of items have tricks like that where you need to exactly follow the instructions or it doesn't work.
I tried removing the nails and it’s impossible. They’re very very very snug. Even punching the backplane out just breaks it and leaves the nails in place with a little piece of board around them. There isn’t enough space between the nail head and the board to slide a kitchen knife and when there is, is breaks the knive’s edge rather than moving the nail.
Very curious indeed to know what your method is.
What I guess I'm trying to say is that it's not IKEA problem, it's budget lines of IKEA products problem. At the lower price range it's hard to expect great durability.
A lot of wooden IKEA furniture sold in Europe is produced in Poland and there are many local knock-offs of IKEA products from other manufacturers. These are either cheaper and even less durable or more expensive but barely match IKEA's ease of assembly and quality of the components. I really don't think that durability is IKEA's greatest problem. ;)
Came here to say just that. Some products are virtually bullet-proof, while others start to show their age after a few months of regular use. For example, cheap melltorp tables can withstand a nuclear blast and even a few cross-country relocations, but anything from their Billy line is already half-way to a trash heap after unboxing. IMMV.
A lot of IKEA stuff I've bought involves one-way assembly -- pounding things together with a mallet. See the EKET cabinets for example. If you reverse it by naively prying them apart, it'll strip the wood.
Or take the backing to any BILLY bookshelf -- it's held in place with ~30 tiny nails. It's virtually impossible to pry the backing and nails off without destroying the backing in the process.
Etc. etc. Yes, some of the pieces can be disassembled, if the assembly consists entirely of cam locks, dowels and screws. But it's certainly not designed for it.
Anecdotally, I just moved apparently. The the last two years my Malm bed was fantastic. Never made a noise no matter what I did on the bed. I could lay, kneel, have my dog run zoomies on it, and it was great. Then I took it apart to move apartments and you would have thought a banshee lived in the joints. Sitting, touching, it didnt matter that thing howled. We tried a few online solutions before doing the ultimate solution: buying a new frame.
Anecdotal but we have several (Expedit, the old Kallax) and they have survived 4 moves, one quite a distance and they are used daily to hold media and in a living room, one was part of my desk for 4 years. They are still in great condition. I expected 2 years out of them and am coming up on 10.
The only exception was one poorly designed under-the-bed drawer (the front gradually falls off due to the impacts if you kick it closed).
The issue is mainly when moving between apartments/houses. All the shifting weight and jostling in the truck simply weakens things too much. It's also not meant to be disassembled, and the particle board easily gets really banged up because it's so soft. And all this is even when trying to protect it with covering pads. (And sadly, none of your tips are going to help either -- fasteners simply pull themselves out of the soft particle board, because the board itself is weaker than the fastener/glue.)
A Billy bookshelf or Kallax shelving unit will hopefully survive a single move, especially if you can tighten/glue things further after it's been moved. But once you're talking 2-3 moves, forget it.
For that reason, for young professionals who move apartments every couple years in their 20's, it often makes more sense to just leave/toss their IKEA shelves/cubbies/units, and buy new pieces for the new place. It isn't durable across moves.
(Obviously I'm talking about "classic" IKEA particle board flat-pack stuff. If you're buying a solid wood table or metal lamp from IKEA then it'll be fine, but that's not what most people are thinking about when they think of IKEA furniture.)