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

In order to better understand Sarah’s dimensions, proportions, posture, and seating line, I made a 1/6 scale manikin using her measurements. The manikins also account for the loose clothing that she often wears; tolerances were also added for comfort.

client interview

My project partner, Sarah, wanted a chair that was both ergonomic and aesthetically pleasing. She has scoliosis, and working long hours on her laptop often causes severe back pain.

thumbnail sketches

sketch models

I made sketch models to experiment with capabilities and limits of the material.

90-Degree

The first seating line I tried was a 90 degree seating line. After doing some research, I realized that a 90 degree sitting angle is not the most ergonomic nor comfortable.

120 Degree

I found out that this seating angle is much more ergonomic than the 90 degree seating angle; however, when compared to the next seating line (135 degrees), this seating line is still lacking in how it leaves the neck at awkward angles and positions.

135 Degree

This seating line, the 135 degree seating angle, is the most ideal ergonomic seating angle according to my research. It alleviates pressure on the disks, and prevents people
from slouching. This is the seating line I decided to move forward with.

workflow

waffling code

During the ideation process, I realized that in order for my design’s geometry to not be constrained by the cardboard sheets, I had to first create the geometric form (3D model) before finding ways of creating it by waffling cardboard panels. I decided waffling was the best method based on my sketch models. I found that it allowed for the greatest detail and freedom in representation of 3D surfaces for the 2D-like cardboard sheets. Waffling also requires a high degree of precision, which is why I decided to use software to design it.

Grasshopper

Shown the the right is the grasshopper code I used to waffle my structures. On the left, I loaded in a curve for the cut frames to run along and the 3D model of my chair. I can also use the contour tool to the same effect; however, the countour tool only works at perpindicular angles! Not shown here is code that allows for the calculation of the intersections and intersection points. I ended up not using it because it would frequently break.

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.