WILMA

DINING CHAIR
DECONSTRUCT_REUSE_RECYCLE
WILMA
DINING CHAIR
ACTONA

Wilma dining chairs are a timeless mid-century design

with contemporary fabrics. Wilma looks great and has
wonderfully comfortable support. The chair is a part of
the Wilma collection and has\manufactured by Actona.
Actona Company A/S is a global furniture company
based in Denmark (Actona Company, 2018). The com-
pany designs and manufactures with their group of com-
panies around Demark, China, Sweden and Ukraine.

Upholstered in light grey 100% polyester Sawana fab-

ric, the chair aims to be easy-to-clean and durable. This
report would future understand the resemblance, the
production materials and also the production methods
using illustration techniques like Sketching and also 3D
modelling of this furniture piece.
EAMES
FIBERGLASS SIDE CHAIRS
Charles & Ray Eames
1951

WILMA Dining Chair takes on the design

resemblance of an iconic design, Eames
Fiberglass Side Chairs. Eames Fiberglass
Side Chairs was designed by two well-
known designers, Charles & Ray Eames in
the year 1961. The intricate and graceful
design of Eames chair comes from the con-
struction base of the Eiffel Tower (Eames Of-
fice, 2018). Made from steel wire and wood,
the chair inimitably combines light, elegant Eames Fiberglass Side Chair
[http://www.eamesoffice.com/wp-content/uploads/2015/02/LI_EM-
forms with structural strength. F_P_20140101_026_P-819x1024.jpg]

Both Wilma and Eames chairs are very sim-

ilar in the overall seating shape, that would
improve the ergonomics and the overall
comfort level of the user. Even though the
materials used in both chairs vastly differ,
both still incorporated the use of polyure-
thane foam and polyester fabric on the
seating portion.
On the first week, the chair was deconstructed to understand
the assembly and the use of materials leading to the pro-
duction of the chair. In this process, there was a clear un-
derstanding that the production of this chair is complex and
tenuous. In the deconstruction of the chair, there was multiple
level of assembly, thus constituting to parts within sub assem-
bly within the whole assembly of the chair.

Disassemble Of Seating Part

[By Author]
DECONSTRUCT
WILMA DINING CHAIR
 SEATING

STAND

FASTENERS

First level of disassembly, also named as the sub-assembly of the dining chair, consist of seating
assembly, stand assembly and the cluster of fasteners. The seating part would be jointed to the
stand assembly by fasteners. This process is done in the last step of the production line, to
enable the chair for easier shipping and cost effective in delivery trips.

SUB_ASSEMBLY
WILMA DINING CHAIR
 CASING BACKING

The parts in the seating are formed by 2 main parts: Casing and Backing. The casing has been
created to be soft and comfortable for the comfort in user sitting while the backing keeps the
shape of the whole structure.

PARTS_SEATING
WILMA DINING CHAIR
 SAWANA
100% Polyester Fabric (PET)
Polymerization
6g

FOAM
Polyurethane (PUR)
600g (0.05 g/cm3)

Factory Workers Using Compression Moulding.

[http://www.customfoam.com/assets/images/general/furniture-process.jpg]

The fabric and the foam combine to form the casing of the chair. The chair is made from 100%
sawana polyester fabric, which is also used in sofa upholstery. The production of Polyester
comes from petroleum by-product, alcohol and carbonoxyl acid going into the “polymerization”
chemical reaction (Craftech Industries, 2018). The foam weighing 600 grams is made from Poly-
urethane (PUR). It is produced by mixing two or more liquid streams. Polyurethane can be made
in a variety of densities and hardnesses by varying the isocyanate, polyol or additives
(Euromoulders, 2018).

CASING
WILMA DINING CHAIR
VENEER LAMINATING
Poplar Plywood
1958g

Veneer Laminating Over Mould.

[http://eimersguitars.com/wp-content/uploads/2012/10/steam1.jpg]

Layers Of Plywood

The material used in the Backing part of the chair is plywood made out of poplar sheets. Veneer
Laminating is the process the part has undertaken. This process involves a split mold and the
use of adhesive, followed by low-voltage heating to bind the layers together (Thompson, 2011b).
The final weight measured on this part was 1958 grams and there was no visible finishing applied
on it.

BACKING
WILMA DINING CHAIR
 FRAME_CAP

FRAME

The sub assembly part “Stand” further dissert into 2 groups of items. The 2 groups of items are
the Frame and the Frame Caps. The Frame part is made out of ferrous metal while the Frame Cap
is made out of plastic material. This materials and the production of them would be covered in
detail in the following pages.

PARTS_STAND
WILMA DINING CHAIR
 TUBE BENDING
Black Anodised Steel

Process Of Metal Tube Bending

[http://www.sharpeproducts.com/Data/Sites/2/media/GalleryImages/294/
WebImages/21pipe_tube-roll-bending.jpg]

SWAGING
Black Anodised Steel

Grand Total
1800g

Mould For Swaging Metal Tube

[http://www.glyne.com/images/swaging5.jpg]

The Frame was manufactured in steel and weighs roughly 1800 grams in total. Due to its hollow
interior of the part, it was initially created out of steel tube extrusion. The tubes then undergo tube
bending and swaging respectively (Thompson, 2011a). To stamp out the holes, metal stamping
has been used on metal sheets . To joint the two or more different pieces of steel together, a weld-
ing process was executed.

FRAME
WILMA DINING CHAIR
 COMPRESSION MOULDING
LDPE POLYETHYLENE
15g (All Caps)

Frame Cap Compression Moulding.

[https://www.camberleyrubber.com/wp-content/uploads/2016/07/Compression-Slider-1-900x500.jpg]

This material of 8 Frame Caps (15 grams) has been identified to be Low Density Polyethylene
(LDPE) (eBay, 2018). It has been labelled as the 4th Resin identification code. LDPE is resistant
to impact (doesn’t break easily), moisture (water-proof), and chemicals (can stand up to many
hazardous materials) (Plastics Make It Possible, 2018). Frame Caps are LDPE plastic pellets that
go through compression moulding (Thompson, 2011a). Compression moulding shapes the LDPE
by squeezing them into a pre-heated die cavity.

FRAME_CAP
WILMA DINING CHAIR
 SCREW

WASHER

Fasteners are important assembly tools that piece together and enable the furniture to come to
final form. However to hold the fasteners in place, the need to use a washer on a screw is un-
doubtedly essential. The following section of the report would emphasis the creation of each item.

PARTS_FASTENERS
WILMA DINING CHAIR
COLD HEADING
STAINLESS STEEL
14g

In Process Of Creating Screw In Cold Head Machines.

[http://www.nationalmachinery.com/images/default-source/default-al-
bum/coldformingprogression.jpg?sfvrsn=0]

The screws are of stainless steel material and they are a total of 14 grams on the scale. Cold
heading process is how the screws are created. This process starts off with a coiled wire or rod
being fed into a cold heading machine and pressed into the die (Acmecompanies, 2018).There-
fore creating a strong yet no waste flow.

SCREW
WILMA DINING CHAIR
 METAL STAMPING
STAINLESS STEEL
10g

Metal Stamping Of Stainless Steel Washers.

[https://media.istockphoto.com/photos/old-punching-machine-closeup-picture-id
515788550?k=6&m=515788550&s=612x612&w=0&h=zdfrTYr8VjLudwN5WytX-
QtS5zbszAZRsoEvCDC7lpC0=]

Similarity the washers are also made in stainless steel however undertake a different construction
method of metal stamping. The process is fast and cheap to operate. It only requires a metal
sheet to be stamped out by the stamping pattern machine (Thompson, 2011a).

WASHER
WILMA DINING CHAIR
Next, this report segment discusses about the assembly pro-
cesses. The assembly process is very important to the design
as it enables the design to be materialised.

Taking Off Stapler From the Chair Seating

[By Author]
HOW_DID_IT_COME_TOGETHER?
ASSEMBLY
 STITCHING

PUR GLUE
HEAVY USAGE

In order to wrap the Sawana fabric around the chair and hold the foam in place, there is a need
to stitching the fabric. Stitching also help to increase the appearance of the chair through the
pattern design. While the fabric rely on stitching, Polyurethane glue has been used for jointing the
foam together with the wood backing.
 WELDING

SNAP LOCK

For the fabrication of the metal frame, the connection of the two parts was fulfilled by welding.
Welding is done by adding filler rod and torching over the parts. The assembly of the frame cap
is done by snap lock onto the frame. The design of the LDPE plastic parts have grooves to en-
able the items to lock into place.
 BOLT UP

The final joint between the frame and the chair is done by bolting the screw and washer up. This
helps to secure the main frame and the chair seating together.
In the selection of material for production, there is a need to
understand the sub-products are sustainable in the long run.
Is it a Linear or Loop equation? In a life cycle analysis, a lin-
ear equation refers to a product being unable to recycle into
the same product while the loop equation enabling the prod-
uct to be able to upcycle or recycle into the original material.

Plywood Part Of Wilma Dining Chair Placed.

[By Author]
LINEAR_OR_LOOP_EQUATION?
LIFE CYCLE ANALYSIS
Overall, this chair maintenance is classified as a infinite loop where the product can be repaired
easily. The manufacturer first obtain a recycled waste to be created into raw material. It would
then continue its path into producing the different parts. The various parts would then have final
touches in place before sending to the assembly line or warehouse area.
(Con’t)
 (Con’t)
Then the assembly of the production would be done manually by workers to fasten the fasteners
into place and pack them into a packing container or pallet for shipping. Customers purchasing
at any retailers, would be applicable to any warranty and returns package. Upon the returning of
a chair, the customer could get a voucher and the chair would be shipped back to see if any part
could be reused.
1. Shreds Recycling Polyurethane foam is very tricky
due to the toxicity of the material. The mate-
rial is a combustible solid and can be ignited
if exposed to an open flame. While burning
vigorously, it produces huge amount of carbon
monoxide and hydrogen cyanide, in addition to
nitrogen oxides, isocyanates, and other toxic
products. The foam could not be recycled into
a soft material due to the process of shredding
different polyurethane textures together and it
Bags Of Shredded Polyurethane Foam.
https://www.puerdayi.com/wp-content/uploads/24(3).jpg would normally be used in carpet underlying
(LEAFtv, 2018).

2. Carpet Underlaying

Detailed Final Carpet Underlay.

https://i.pinimg.com/originals/80/40/d6/8040d68cb943fcb81bd6b3dc8b098ebc.jpg

1. Plywood
Boards of Plywood Stacked.
https://static1.squarespace.com/static/54d95c4ce4b0b3595f748f29/t/
5a5c50ce24a694da4abb758d/1515999448614/plywood-stack.jpg
Shredding the backing of the seating would
end up with wood chips. Plywood could be re-
cycled into compression wood or medium den-
sity fibreboard. Due to the foam being glued
onto the backing of seating, there is need to
pick all the foam out before shedding the ply-
wood. This is to ensure that the plywood could
be shred properly or it would cause tangles or
jam equipment (Nottinghamshire, 2018).

2. Wood Chips
Handful Of Wood Chips.
http://www.ljmtreecare.com/wp-content/uploads/2016/02/Wood-Chip.
jpg

3. MDF Boards
Detailed View of MDF Board.
https://sc01.alicdn.com/kf/UTB8fp8ec9nEXKJk43Ubq6zLppXap/Ve-
neer-Block-Board-MDF-Board-Laminated-Wood.jpg_350x350.jpg
2. Steel Sheets

Sheets of Stainless Steel.

https://i.ebayimg.com/images/g/PjoAAOSwXYtYzXMC/s-l300.jpg

1. Molten Steel

Molten Steel In Furnace.

https://www.insidermedia.com/uploads/news/molten-met-
al-571823_960_720.jpg

This recycling of the metal framing is more sustainable than the foam. The anodised steel could
be melted directly into molten steel and created into steel sheets. However in the process of recy-
cling, there are a lot of energy and materials used to melt the steel (Brownrecycling, 2018).
 2. Plastic Pellets

Plastic Pellets.
http://admiral.market/en/images/products/1_grade_lldpe.jpg

1. Plastic Shreds

Plastic Being Shredded Into Strips.

https://i.ytimg.com/vi/XyAzp08jAkY/maxresdefault.jpg

This portion of the plastic would be shredded into plastic shreds and then melted into pallets
(Sciencing, 2018). It would then be sent to washed with biodegradable soup and water.
The plastic pallet could be use to shape into the frame caps.
Wilma Dining Chair Flipped Over.
[By Author]
ECO_SCORE
ECO_INDICATOR_CALCULATOR
BY_LIFE_CYCLE_STAGES
ECO_INDICATOR_CALCULATION
BY_MANUFACTURING_PROCESS
ECO_INDICATOR_CALCULATION
Detailed Shot Of Chair Overall Construction.
[By Author]
Acmecompanies.com, 2018. Cold Headed Parts - Wheaton, Illinois. [online] Available at:
http://www.acmecompanies.com/cold-headed-parts.html [Accessed 11 Aug. 2018].

Actona Company, 2018. ACTONA. [online] Available at:

http://www.actonacompany.com/products/actona/ [Accessed 11 Aug. 2018].

Anon, 2018. [online] Available at:

https://www.snowymonaro.nsw.gov.au/DocumentCenter/Home/View/4877 [Accessed 11 Aug. 2018].

Brownrecycling.co.uk, 2018. [online] Available at:

https://www.brownrecycling.co.uk/wp-content/uploads/2016/11/steel-recycling-infographic.jpg [Accessed 11 Aug. 2018].

Craftech Industries, 2018. How is Polyester Made? - Craftech Industries - High-Performance Plas-
tics - (518) 828-5001. [online] Available at:
http://www.craftechind.com/how-is-polyester-made/ [Accessed 11 Aug. 2018].

Eames Office, 2018. Eames Plastic Armchairs | Eames Office. [online] Available at:
http://www.eamesoffice.com/the-work/eames-plastic-armchairs/ [Accessed 11 Aug. 2018].

eBay, 2018. Round Plastic Blanking End Cap Caps Tube Pipe Inserts Plug - Round Tube Plugs |
eBay. [online] Available at:
https://www.ebay.co.uk/itm/Round-Plastic-Blanking-End-Cap-Caps-Tube-Pipe-Inserts-Plug-Round-Tube-Plugs-/232800417092
[Accessed 11 Aug. 2018].

Euromoulders.org, 2018. What is polyurethane foam? | Euro-Moulders. [online] Available at: https://
www.euromoulders.org/polyurethane-foam/what-is-polyurethane-foam [Accessed 11 Aug. 2018].

LEAFtv, 2018. What Types of Foam Can Be Recycled? | LEAFtv. [online]

Available at: https://www.leaf.tv/articles/what-types-of-foam-can-be-recycled/ [Accessed 11 Aug. 2018].

Nottinghamshire.gov.uk, 2018. [online] Available at:

http://www.nottinghamshire.gov.uk/planningsearch/DisplayImage.aspx?doc=cmVjb3JkX251bWJlcj01ODE2JmZpbGVuYW1lPVx-
cbnMwMS0wMDI5XGZpbGVkYXRhMiRcREIwMy0wMDMwXFNoYXJlZEFwcHNcZGxnc1xwbGFuc1xwbGFubmluZ1xmLTI4NDhcM-
jU5MS1iIHdyYXAgd29vZCByZWN5Y2xpbmcgZ3VpZGUucGRmJmltYWdlX251bWJlcj05JmltYWdlX3R5cGU9cGxhbm5pbmcmbG-
FzdF9tb2RpZmllZF9mcm9tX2Rpc2s9MjUvMDYvMjAxMyAxNDoyOTozOQ== [Accessed 11 Aug. 2018].

Plastics Make It Possible, 2018. Professor Plastics: Highlights of Low-Density Polyethylene. [on-
line] Available at:
https://www.plasticsmakeitpossible.com/about-plastics/faqs/professor-plastics/professor-plastics-high-
lights-of-low-density-polyethylene/ [Accessed 11 Aug. 2018].

Sciencing.com, 2018. [online] Available at:

https://sciencing.com/ldpe-recycled-6360593.html [Accessed 11 Aug. 2018].

Thompson, R, 2011. The manufacturing Guides: Product and furniture design.

Pg 14, 52, 76, 84, 90

Thompson, R, 2011. The manufacturing Guides: Prototyping and low-volume production.

Pg 88

RESEARCH_DOCUMENTATION
REFERENCES