We set out to design an outdoor lounge chair that encourages reflection, inspired by the earth’s topography. The form is a result of research in fabrication and influence from organic aesthetics. Processes: CNC routing, mill, metal laser cutting, tapping, tube bender, CAD/CAM
The project was developed over 20 weeks. The primary sitting position is reclined; however, there are also secondary positions that can support other sitters.
In early prototypes I used anthropometric data with scaled down
models to design the form. Using wood helped explore different
fabrication processes and their strengths.
I created CAD models to compare form and manufacturing choices, aiding quick decisions. I performed FEA analysis to compare load cases on the frame and set up CAM operations for CNC routing of the wood.
I built three full scale variants using intended joinery techniques to determine reproducibility. We could then customize our form around our manufacturing method. For example, we discovered that our CNC method enables the creation of profiles with interesting calligraphic variations.
We compared a dozen wood species and ultimately sourced FSC-certified Sapele Mahogany. For each board size, I created a CNC routing CAM operation optimized to minimize waste. Finger joint operations were integrated into the cut file reducing our total operation count.
I measured the linear spring back between the die and output radius on our tube bender. I then built custom dies to precisely and repeatedly bend the aluminum frame. Structurally, I added a rear support leg to prevent bending and a cross bar to prevent racking. I also tapped all holes for fasteners.
Tolerances were critical to this multi-part assembly. I designed laser cut brackets out of aluminum tubing with slots to counteract tolerance stack up. Then I laser cut spacers and brackets designed to all sit flush.
All 19 chair profiles are secured on a threaded 3/4in aluminum dowels with hex nuts. The large fasteners are then covered by the outer profile with security screw heads for peace-of-mind.
The chair was placed around Stanford campus over three weeks where I observed how people interacted with it.
The form of the chair was conceived in collaboration with teammates Aisha, Lucia and Alex. I designed the final build model, fabrication techniques and tooling processes. I built each of the 400+ parts, with extra hands for assembly.