The concept of this chair came about the desire to create a chair that was beautiful, functional and left little waste. The entire chair was made from 1 piece of Bamboo plywood. (Well the initial design was for that, however after the chair had been made I realized it needed a stabilizer bar and the leg to be a bit thicker). As well, i felt that there would be a way to design and build a chair that over all was not too expensive and could still be eco-friendly.
1 sheet of 1/4" bamboo plywood 4'x8'
2 sheets of 3/4 particle Board 4'x8'
1 sheet of semi-rigid material to skin the top of the form
600 wine corks
5- Crown Bolt 1/4-20 x 13mm Zinc-Plated Steel Type-A Insert Nuts
5- Crown Bolt 1/4-20 x 70mm Coarse Steel Hex Drive Connecting Bolt
7- 8 x 1-1/4 HighPoint Round Washer Head Screws
AMF Safecoat Safe Seal or other eco-friendly clear sealer
Band saw or other method to cut wine corks in half
Electric sander or hand sander with assortment of grits
An assortment of clamps
Nail gun w/ 2" nails
Screw gun with screw bits and and 1/4" drill bit
CNC machine or a hand router and patience
Vacuum form with large enough bag to fit chair and form
Optional heat blanket if your shop gets cold at night
Step 1: The Plan
I have attached the full AutoCad files for the shape of the chair and the CNC machine. I designed the shape of the chair to the human body to maximize comfort. One could alter the shape of the chair and update the CNC file as needed. The CNC file will cutout all the pieces needed to build the form for the chair. It might seem as though the form costs a lot of money, however if built properly it can be used over and over to re-produce this chair.