I always wanted to make a bent plywood chair so I went ahead and made this prototype. I used compression mold to curve the plywood and a water based resin glue to put the bendy ply together.
I decided to make a simple design that would be broken down into 7 different pieces:
• Front leg (x2)
• Back Leg (x2)
• Arm rest -connecting front and back leg- (x2)
The seat is elegantly supported from the edges of the branching legs creating a bridge between the front and the back legs. The ramification of the legs not only split in two directions with the same angle to each side generating a consistent flow in the legs but also creating the armrest. The biggest design challenge was creating the partition in the legs that become part of the armchair and seat. The front legs start thick from the ground and bend forward to become the seat and also backwards to become the armrests which then come down as the back legs. The ramification was the whole concept around the project, which made it an interesting detail.
Material: Poplar bendy ply and red oak veneer
Molds: Random scrap plywood
Strip of plastic (x2) for quick and clean unmold
DAP® Weldwood® Plastic Resin Glue
Biscuit Joints to put the 7 pieces together
Step 1: Testing Ergonomics
Making a full size prototype is helpful to check dimensions and proportions.
Testing the ergonomics to verify if the angles and lengths are comfortable.