Duration
2022
Levescy Lounge Chair
Responsibilities
Product Design, CAD Modeling, CNC Routing, Ergonomic Studies
ABOUT THE PROJECT
Project Brief
Design a functional piece of furniture that maximizes material efficiency while minimizing waste. The design should prioritize simplicity in both form and manufacturing, ensuring it can be easily produced at scale with consistent quality.
THE DESIGN
Iterative Discovery
At the outset of this project, my primary goal was to identify a material that was both cost-effective and versatile. Environmental considerations also led me to avoid plastics due to their negative ecological impact. After evaluating various options, I chose plywood as the core material for my furniture design, appreciating its affordability, adaptability, and sustainability.
Design Logic
Given the project constraints, I had to be creative with my approach to achieving a dynamic furniture design. Instead of steam bending, which requires extensive setup, I utilized kerf bending to create complex curves in the plywood. This technique involves cutting shallow grooves into the surface, enabling the flat material to flex and bend. Kerf bending leverages the layered construction of plywood, a composite material, to achieve smooth, adaptable curvature with minimal equipment.
Final Design
In the final design, I prioritized comfort and visual appeal. The innovative aspect of this design lies in its efficiency: each component is cut from a single sheet of plywood using a CNC router. The flat pieces are then transformed into dimensional forms through kerf bending. To enhance both functionality and aesthetics, I incorporated thick felt as an affordable alternative to traditional upholstery. This material not only adds a pop of color but also provides extra comfort for the user.
The following highlights the manufacturing process behind this design.
