The Seat is the largest item within the collection, and likely the most challenging, due to the many different processes and elements, some of which I have very little to no previous experience in. However, i feel that i need to challenge and hopefully improve upon my skills to produce this interior based collection.
Generally, the seat can be constructed in two main ways. Through research of traditional sofa and chair (furniture) making processes, a very basic carcass is constructed in wood, then webbing is stretched tightly and tacked to the carcass form to create a relatively rigid yet still hollow structure. This method is used so that the portability of the product will be accessible through this method of weight and by association, cost control. The sofa/seat is then filled out with multiple layers of foam, wadding etc attached with upholstery/industrial grade spray glue , and then the material is applied etc. However, the form i want is quite eccentric, and therefore the carcass would have to be very complex, and would take a lot longer to make than a straightforward sofa with a straight back.
An alternate, more modern method to produce this, in a batch production process of vacuum forming the curved basic structure. The carcass the former would be curved on one axis, as opposed to two, made from layers of CNC’d hardwood ply, and laminated with flexi ply to cover the gaps. Up to three layers of flexi ply would be vacuum formed to the jig then a template would be laid over the top of the vacuum formed ply to cut out the curved line of the seats structure. A solid plywood base board cut to fit the curved back form, would be glued along the bottom of the curved piece and screwed in from the back of the seat, behind the curved form. The seat section will be covered in a few layers of wadding or thin foam and upholstered, so that the seat cushion can be removed and the ply underneath wont be visible. Support beams can be attached and hidden to the underside of the plywood base to spread the weight over a larger surface area.