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Overview
The project started with a brief to develop a budget task chair for the Japanese market. With so many constraints around cost and manufacturing complexity, design differentiation in this category is typically limited to the overall silhouette of the chair.
Our design approach explored how transluscency and 3D knit technology could be used to create a more refined appearance and bring additional comfort to the product category. The backrest is wrapped in a semi-transparent 3D knitted mesh that reveals the inner structure of the back, a series of visual rays that extend outward from the centre. This design feature creates depth, layering and a sense of visual sophistication while still meeting cost, comfort & production requirements.
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Design Process
The design process began with sketch exploration, followed by VR sketching, CAD development, and 3D printed prototypes to evaluate form, proportion, and detailing.
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Backrest & Lumbar
The backrest structure solved many production problems commonly found in mesh task chairs. The cored out frame is light & strong, the wrapping fabric hides potential sink & flow marks in the plastic, and the entire backrest can be molded in one piece without the need for sliding cores or further assembly.
The cored out frame also creates space for a vertically sliding lumbar pad inside the backrest, using a design that adds extra spring comfort. This level of movement and support is unmatched in low price task chairs.
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3D Knit Development
The use of 3D knit both opened up new design opportunities in the backrest and reduced the material waste from fabric offcuts. Produced in one piece, it reduced cost for manufacturing and more easily wraps 3 dimensional areas normally sewn from multiple patterns with complicated stitching.
Over 20 iterations of 3D knit were made to test different patterns and acheive the perfect balance of aesthetics, support, and weave comfort.
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Product Launch
Together with the team at PLUS, 6 colourways were developed for the Japanese market. The Mari chair is available with optional adjustable armrests and an adjustable headrest.
