After CAD development phase is completed, the mock up phase for building the chair is started.
Welding the center of reinforce rods on the bottom of the chair.
The mock up phase is divided into two major subjects: the metal and woodworking.
Instead of using laser or plasma cutting techniques, the side frame is made by 4 mm flat bar, cut and welded together. The actual plan was also using stamping machine to shape it up, while the realization is pretty filled up with high skilled craftsmanship. The measurement was made manually, using patterns printed in 1:1 scale on a sheet of paper.
The leg, which is also the main structure of the frame is made from three different kinds of applied metal. Tubular pipe (1” in diameter), solid rod (14 mm in diameter), and flat metal sheet (50 mm width) are combined together based on the drawing.
Meanwhile, the wood panels were even more radically made, started from cut down a coconut tree to get a flat board as chair’s seat and back.
Assembly tryout between the leg and side frame, to ensure both can be joined correctly.
The drilling phase, using vertical drilling machine. The profile of the holes were made in a counter-sank to let the flat head bolts flushed in nicely.
The pre-finished side frame and leg were welded together using TIG (Argon (Ag) inert shielding gas) welding technique to fill up all gaps between the parts.
The finished structure (leg and side frame) is sanded to create a smooth surface before it went for painting phase.
The sanded structure ready for painting phase. Early treatments on the structure is done by several phases to ensure that the painting phase will be successful.
Structure painted in powder based chrome (not dipped), after being baked in the oven (200° Celsius) for about an hour.
After cutting the planks using patterns made by 1:1 scaled paper, the finishing phase for the wood planks is using Nitrocellulose lacquer.
The pre-assembly phase, using printed papers to replace the panels.
Joining the planks on the metal panel using pre-drilled insert nuts and flat head bolts.
The finished chair and its mock-up maker. The gallery of the chair can be seen here.
Just visited one of the remaining outdoor furniture manufacturer in Curug, Tangerang, West Java named CV (Comanditaire Venootschap) Property. Located far in the village, with rice field lies ahead, this factory is a survivor from 2005.
Frame samples are found everywhere in the facility.
The business mostly involves simple aluminum welding, cutting and bending, combined with high level of weaving techniques by home based craft persons who lived surrounding the factory.
The products are exported to overseas customers (usually Northern Hemisphere (United States and West Europe)), either to be sold on retails or projects. Beautiful combinations between aluminum based frame and various synthetic wicker (or loom) have given a nice looking furniture, with thousand of models from the geometric shaped up to the organic ones.
Stacked frame, ready for weaving.
The level of craftsmanship in this industry is definitely exceptional. They don’t really use proper tools for building the frame (just using their good sense), as well as more exceptional weaving techniques that able to provide wide range of weaving types.
Loom weaving machine that produces loom sheets. This one is huge.
The other types of weaving materials is loom. It is a paper covered cord, with paper like surface (of course) and can be finished in colors. The output of this monster is loom sheets, and sent to Cirebon, West Java for further process. The loom sheets can be applied on the aluminum frame as well.
Finished products (side chairs) are covered and ready for shipment.
Let’s hope this industry lasts for more years to come, as it involves a lot of home-based labors (women as well). Unlike a post office in the village that has been abandoned, and nothing (except the building) left over.
This is an attempt to create M6 metric threads for both external (male) threads and internal (female) threads. The basic procedure is by using rail revolve command, with precised measurement for profile curves, rail curves, and axis.
Step to create: