Cardboard Chair
Research.
Research, material testing and visual exploration carried out in preparation for designing and building the final cardboard chair.
Cardboard Bridge
Designing and constructing a cardboard bridge spanning 300mm, built to support 10kg using no glue or tape. Only folding, slotting and interlocking techniques were used.
Bridge Sketch
Holding 10kg
Design Strategy
Initially I thought of utilising triangular prisms, as triangles are the strongest shape. For balance, I decided to use two identical prisms where each one holds an equal weight on either side of the circular dumbbells.
Observations
Upon placing the first dumbbell the bridge did not change form. However, when placing the second 5kg, the bridge started to bend where the edge of the dumbbell made contact with it. Despite this, the bridge held up and kept its form really well.
Material Behaviour
Using end grain helps hold the object up without getting crushed, which will be useful for the chair project. Where force is applied downwards, end grain should be oriented parallel to that force.
Material Testing
An exploration of pizza box cardboard through scoring, cutting, bending and shaping. Building material awareness of texture, flexibility and structural behaviour ahead of the main chair project.
Curved Along Corrugations
Bending the cardboard parallel to the corrugations produces a smooth, even curve with minimal resistance.
Exposed Corrugation
Removing the outer layer reveals the internal corrugated structure, showing how the material achieves its strength.
Sliced Surface for Cleaner Folds
Slicing the surface layer allows the cardboard to fold cleanly and precisely without crumpling or buckling.
Scale Model Testing
A small-scale cardboard model built to test the structural approach, joint logic and overall form before committing to a full-size build.
The shape holds due to the components locking together using slot joints. However the "padding" does not hold its shape due to the springiness and rigidity in the cardboard causing it to spring open and not holding its flattened shape.
The spring in the layers of cardboard supplies a softer force on a human's bottom. Additionally, the angled back would allow for a nice funnelled back position helping to hold the person in the chair.
Slot joints work the best for planar building. Additionally, slicing one of the layers of cardboard allows for the bends to fold perfectly with no bending cardboard surfaces.
Typology Research
A collection of 50 chair images gathered as visual research, focusing on lounge chairs. Each image explores a different approach to form, structure, material and aesthetics. Detailed analysis is written for 30 of the chairs below.
01
Feet kick up higher than the head, inverting the typical seated posture to promote relaxation and redistribute body weight.
02
Concaved interior molds to the human body, allowing the human to be one with the chair and not slide off the sides.
03
Angle of lumbar support can be changed for any position and different anthropometrics.
04
Negative space archway helps hold and support the weight of someone laying across the seat.
05
Angle of the Buttock-popliteal allows you to sink back into the chair, making it easier to relax on your back.
06
Fabric curved seat molds to posture and body, with a pillow to support the head.
07
Organic curves and foam work together for comfort, softening the transition between surfaces.
08
Slot joinery and grain alignment provide structural strength without fasteners.
09
Cardboard surface offers a smooth contact face for comfort against the body.
10
Balances circular, unique aesthetics with smooth foam and fabric finishes for comfort, incorporating armrests for full support.
11
Large surface area allows for multiple seating positions, improving anthropometric comfort across different users.
12
Angle-adjustable design accommodates both laying and seated positions.
13
The idea of movement, rolling the weight onto your back slowly using a mechanism. Facing the sky for ultimate comfort and even weight distribution.
14
Having size allows for multiple people to rest on the chair. Using bright colours helps the product stand out in an environment.
15
Complexity helps the ergonomic feel of the chair, allowing for the perfect gaming posture.
16
This chair is one of my favourites. It truly moulds to the person's body, allowing any human to fit comfortably. It also introduces the sensation of unusual but satisfying relaxation positions.
17
Adjustable posture, control how far you lean back.
18
How low to the ground you sit changes the feel entirely.
19
Negative space used for function.
20
Negative space used for suspension.
21
Rocking and reclining, two functions in one.
22
Layers of planar material following one 2D profile, extruded into 3D.
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23
Bucket form holds you in place, with a cosy feeling wrapping around you.
24
Chair and reclining stool combined, with a large pillow form.
25
Strings mold the form to your body like a hammock.
26
Curved fabric matches the curved timber, unifying the bending of both materials.
27
Simple 2D profile.
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28
Square texture for a unique feel and eye-catching aesthetic.
29
Timber support curves in one unified form with the foam seat.
30
Organic shapes joined together to make a seat.
31
Single molded form.
32
Large surface area for comfort, like a mattress.
33
Unique bubble texture for a sensational feeling.
34
Enclosed for a safe, cosy feeling, and hanging for a rocking sway movement.
35
Sit in it like a donut, spreading your legs for comfort.
36
Classic.
37
Similar to 34, cosy feeling inside a bubble.
38
Simple but in a vibrant colour to stand out and be emphasised.
39
Simple 2D profile that incorporates colour to make it look more complex.
40
Crazy aesthetic but comfortable form.
41
Large form, ideal for comfort.
42
Rocking and laying.
43
Large beanbag that also holds the legs instead of just the upper body.
44
Entirely foam for lightweight and extreme comfort.
45
Fully engulfs the body with massagers for a full body sensation.
46
Two modular parts that work together, separable for flexibility.
47
Unique sculptural form that doubles as a statement piece.
48
Rocking lounge, leaning back shifts your weight for a natural recline.
49
360° rotation adds function without changing the form.
50
Bent timber follows the body's curves, material and form working as one.
Folding Products
A study of folding and flat-pack products to understand how materials and structures can collapse, pack down, or transform through folding mechanics.
Collapsable form, structure folds entirely flat for storage.
Flat pack fire pit, slots together without fasteners.
Flat pack crate, folds into a rigid box from a single sheet.
Folding keyboard, hinged sections collapse to half size.
Kinetic door, panels fold and stack to open the space.
Flat pack boxes, scored folds allow a flat sheet to become a rigid container.
Paper stool, layered and folded sheets create a surprisingly strong seat.