Blending the ergonomic support of a car seat with the relaxed profile of a pool lounge, this flat-pack chair was a deep dive into unfamiliar territory, as this was my first experience with product design. By using CNC-routed plywood, the focus was on three main pillars: mastering the living-hinge system, ensuring full adjustability, and prioritizing storage. To achieve the latter, the back and head panels were engineered to detach, allowing the entire piece to be stored completely flat.

The process relied on constant refinement, specifically to get the posture and hinge flexibility just right across multiple recline positions. After moving through iterative sketching and scaled cardboard models, 1:4 scale plywood prototypes helped narrow down the form and pattern. A continuous profile was shaped using slotted joinery and flexible sections that allow the wood to mimic the curve of the body. A major part of that physical labor involved three weeks of dedicated sanding to achieve the final finish, rounding the corners and assemblage.