Construct

jan - mar 2024 | product design & engineering, DFMA

3 modes, 9 settings, all in 1 chair. 

The Construct chair adapts to your situational needs, designed to let you construct the chair you want to sit in.

It took me 8 weeks to turn my idea into a functioning and comfortable chair. I documented my design and engineering process in a physical companion book, proudly displayed next to the Construct chair in the Segal Design Institute atrium as part of the Graduate Showcase.

Take a look at the PDF of my companion process book!
Photo of fully assembled Construct chair
What defines a chair?
The Construct chair is an exploration of this. The prominent handles and tactile combination of plastic and wood invites interaction, allowing the user to define the chair that they want to sit in. The flexible mesh contours to the definition of the user’s body, providing a comfortable and supportive sitting experience. The raw aluminum sidewalls define the form of the chair, while the cutouts and profiles give it levity and transparency. Fasteners, marks, and stitches are visible in testament to how it was constructed.
My contributions
This was a personal project. I defined my original design intent, explored different adjustment mechanisms, and figured out how to make Construct a real working chair. This was executed in 8 weeks within a $1000 budget.

I am deeply grateful for Hemmant Jha, Eric Capper, Greg Galuszka and his crew at MJ Celco, Robert Taglia, the Segal Family, and the Segal Design Institute. I couldn't have done this without their wisdom and support.
Construct overview with modes and exploded assembly
Original Design Intent
I believe that the best products enable a healthier lifestyle: I love my standing desk and how it adapts to my situational needs. My original design intent was to make a chair that had two modes: one that was for relaxing in ("off"), and one that primed you to be engaged and ready to work ("on").
Initial sketch of original design intent

Mechanism Exploration

Before thinking too much about the design of the chair, I decided to start exploring different adjustment mechanisms. I wasn't sure what was feasible and I wanted to design system that was easily understandable and made the barrier to changing modes as low as possible. But above all else, I wanted it to be fun and something that users enjoyed interacting with.
Sketches exploring different mode switching mechanisms

Choosing a Design Direction

I wanted to combine the textile and linkage ideas. The flexible nature of soft textiles allow them to drape across supports while contouring to a user's body to form a supportive sitting surface: what would happen if you changed the position of the supports, and what is the best way to change the shape of the textile (and thus, the chair)?
First idea and cardboard prototypeSecond idea, and final evolution combining the two ideas

Functional Prototyping

Having decided on using a textile with two fixed ends and a third actuating bar used to change its shape, I needed to figure out how to make that work in a functioning chair, as well as the appropriate dimensions. In other words, it was time for full-scale prototyping.
First prototype of Construct
CAD of second prototype with dimensions
Handwritten title: "Proto 2"
Evaluation of Prototype 2

Final Design

The materials and industrial aesthetic I chose were a happy medium between form and function. In an attempt to reduce the physical and aesthetic weight of the chair, I took design cues from the bamboo scaffolding I grew up surrounded by in Hong Kong that has both rigid structure and visual transparency. This inspired the matrix design of the sidewalls, the green mesh, wooden dowels, and plastic hardware. I also considered the assembly, incorporating features that make it easy to construct and deconstruct the Construct chair.
Final CAD design of Construct

Fabrication

And finally, time to turn this design into a real, working product. I turned the handles down on the lathe, bored the wooden dowels and press fit the pins, tapped the bracing rods, and sewed the textile assembly. After problems with the waterjet, I was fortunate to work with MJ Celco, a metal forming factory, to manufacture the aluminum sidewalls.

Seat assembly highlighting materials and transparency
Tapping steel bracing rods
Showcase
I was honored to show and present the Construct chair to members and donors of the Segal Design Institute, as well as being part of the Graduate Showcase!
Film photo of me sitting in my Construct chair, holding my process book