design process

Lonc seaser

Side view sketch of the basic forms, starting point being a lounge sit angle with tilted arm rests.

Left: Side view sketch of an alternative with a smaller basis and a hole underneath the arm rest Side view sketch presenting an alternative of a smaller basis and an opening below the arm rest. Right: A similar sketch with a more organic kind of form

First computer CAD model, combining the (main)basic form with ergonomic dimensions

CAD model in which the sketch ideas are translated into a 3D form

Mockup, constructed out of layers of Styrofoam and based upon the dimensions of the CAD model

Ergonomic tests using the mockup

Finetuning the (main)form as well as the ergonomic dimensions of the CAD model

Real size CNC computer milled prototype. The prototype is milled out of solid MDF wood out of 3D computer data of the finalized CAD model.

Coating process of the MDF prototype

Prototype with color coating

Visualization of the desired parting lines of the production mould. Hence the best position for placement of these lines can be evaluated upon the prototype

Finalised CAD model, ready for tooling and production

Transparent view of the CAD model to show the cavity in the base in which extra weight can be added

Technical drawing with specifications for tooling and production

CNC computer milling of the mould out of solid aluminum. In this way the highest mould quality can be reached resulting in a product with a high level of finishing

The production mould consists of 4 different parts. 4 piece production mould ready for use

The first out of tool, which is the very first product out of the production mould. After this the mould can be fine tuned and a texture and coating can be added to the mould