TORUS CHAIR

torus chair

cardboard chair Project

I designed the Torus Chair for a project in Fall of 2021. We were tasked to design and build a chair for our partner that caters to their needs and wants. The chair must be made with no more than 5 sheets of 4 by 8 feet of cardboard, and no adhesives or fasteners are allowed in its assembly.

Ideation

manikin models

To better understand Sarah's dimensions, proportions, posture, and seating line, I created a 1/6 scale mannequin incorporating her measurements, loose clothing, and comfort tolerances.

client interview

My project partner, Sarah, wanted an ergonomic yet stylish chair to alleviate the severe back pain caused by her scoliosis and long laptop work hours.

thumbnail sketches

Ideating and exploring different mechanisms.

sketch models

Sketch models for experimenting with cardboard material.

90-Degree

I initially tried a 90-degree seating angle but found through research that it is neither ergonomic nor comfortable.

120 Degree

This angle is more ergonomic than 90 degrees but less so than 135 degrees, as it still leaves the neck in awkward positions.

135 Degree

Research shows the 135-degree seating angle is the most ergonomic, reducing disk pressure and preventing slouching, so I chose to proceed with it.

workflow

waffling code

To avoid constraints from cardboard sheets, I first created a 3D model and chose waffling for its ability to precisely represent detailed 3D surfaces with 2D cardboard. I used software for its precision in designing the waffling structure.

Grasshopper

On the right is the Grasshopper code for waffling my structures, while on the left are the chair's 3D model and cut frame curve. Though the contour tool achieves similar results, it only works at perpendicular angles. Intersection calculation code is not shown, as it frequently broke and was unused.

refinement

angled panels

For this concept refinement model, I played with how much I could angle the panels. Angle the panels decreases shearing and allows for a more stable construciton.

refinement

angled panels

I found out that angling both axis's of paneling was not a good design decision. Although it looked great in some angles, the design's inner geometric details often became submerged. The curves that made up the inner surfaces of the chair also became flattened. I decided that the best course of action was to only angle one axis of panels for stability and aesthetics while keeping one axis perpendicular to preserve the chair’s geometric form.

preserving form

After realizing that one axis of paneling must remain perpendicular for the geometric form to be preserved, I decided to attack the issue of material restrictions. I realized that there was not enough cardboard to create the form I desired. My solution was to use thin strips to suggest the form of the chair.

first model

seating cage

For this concept refinement model, I played with how much I could angle the panels. Angle the panels decreases shearing and allows for a more stable construciton.

first model

Chair dimensions

For this concept refinement model, I played with how much I could angle the panels. Angle the panels decreases shearing and allows for a more stable construciton.

Creating Form

I found out that angling both axis's of paneling was not a good design decision. Although it looked great, like a blooming flower, from some angles, angling both axis's causes the inner geometric details to become submerged. The curves that made up the inner surfaces of the chair became flattened. I decided that the best course of action was to only angle one axis of panels for stability and aesthetics while keeping one axis perpendicular to preserve the chair’s geometric form.

creating form

After realizing that one axis of paneling must remain perpendicular for the geometric form to be preserved, I decided to attack the issue of material restrictions. I realized that there was not enough cardboard to create the form I desired. My solution was to use thin strips to suggest the form of the chair.

creating base

After realizing that one axis of paneling must remain perpendicular for the geometric form to be preserved, I decided to attack the issue of material restrictions. I realized that there was not enough cardboard to create the form I desired. My solution was to use thin strips to suggest the form of the chair.

testing

After realizing that one axis of paneling must remain perpendicular for the geometric form to be preserved, I decided to attack the issue of material restrictions. I realized that there was not enough cardboard to create the form I desired. My solution was to use thin strips to suggest the form of the chair.

testing

After realizing that one axis of paneling must remain perpendicular for the geometric form to be preserved, I decided to attack the issue of material restrictions. I realized that there was not enough cardboard to create the form I desired. My solution was to use thin strips to suggest the form of the chair.