Rachel Harding approached us with a vision, to push the conventional uses of Solid Surface by designing and creating a chair that was to form through inflation. This required the development of fabrication techniques and jointing methods that would cope with both the heat and pressure placed on the joints during the inflation process.

The project looked at utilizing Autodesk software to model and simulate the projected outcomes as the method developed. The project also questioned the use of high cost formers and replaced the need of 5 axis molds by machining profiles that allowed for the deflection within a basic slab mold.

Digital CNC fabrication was used to create two profiles, machined to varying depths, and then bonded together to produce an envelope that would deflect to precise degrees when air pressure was applied. Combined with the use of the “loose guide” former rather than a restrictive mold allowed the shape to balloon organically upon inflation resulting in a very natural form not seen before in Solid Surface.

Location: Future Makers
Designer: Rachel Harding
Client: Dezeen / Autodesk