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penccil: Making a Cool Chair, Davidson
Making a Cool Chair, Davidson
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In 2009 I had this idea of making a rotationally molded outdoor lounge chair. From an economic point of view I decided to make the mold my self from sheet steel which would limit the design to non compound surfaces. During the computer modeling process I rendered the form form in a punch metal finish to see how long the rendering would take. 12hrs later and with only 20% of the image was rendered I saw what was to become the Cool Chair!
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Cool Chair, Cologne 2011
Early sketch of what was then called the Duck Chair.
Several paper models were made just to plan how the perforated steel would be cut. The key to the design was to hide all the joins making a seamless form.
Cutting the sheet material with these two tools
Positioning the edge wire.
Matching the cut perforated sheet to create an invisible join.
The chair is made from several panels which are hand cut and formed from perforated steel sheets.
Rolling the inside hole sections
Welding the last seams
The moment the chair exited the powder coating machine.
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