Outdoor Garden Lounge Chair

Hi enthusiastic makers,

In this Instructable, I am going show you how I manufactured this outdoor lounge chair. I made this project for my GCSE project. The purpose of my project was to increase comfort for users with Eco friendly design. The materials i used were oak for the frames and flexi plywood for the resting area.

Aluminium

Oak

Flexi plywood

Drill

sandpaper

CNC machine

Clasp

I made made designs using solidworks. I created a simple shape for the frame and added a curved surface for the back rest. For durability i added extra support frames beneath the chair. Once you are happy with the design, then you are ready to transport the file to a CNC machine

Once the machine has finished cutting the frame you can remove them from the compartment. The above pictures shows how I removed the extra wood, I used a file to remove the slot pieces

I used sand paper to remove sharp edges and make the surfaces even

I used 2 clamps to ensure the wooden pieces don't move. Then i collected some clamps from the local DIY store and used a screwdriver to insert screws into the wood. Once this was done the wooden legs were one piece and stable.

I got some aluminium strips and cut them so they can fit the edges of the back blank. I get a drill and made a hole in the top center. To ensure it was the middle i used guides and made a mark on where to cut.

This was the eighth process, this was when I was cutting the flexi plywood in shape so it can fit the chair. I first measured the flexi plywood then cut it to my specification and then started to fold it in the areas where it can fit. The process was very tricky and confusing at first but I finished it.

Then i done the joint stage. I needed to add holes in the metal so they can be screwed into the chair. I then used a metal wool to make the edges smooth. To make the holes I used a drill and made holes in them.

Now i refined the surfaces again. I can ensure my product was safe. I used clamps to hold down the chair . But I needed to sand it after I made the whole chair. This was because I needed to wax the materials later and if it was smooth then it makes it easier to spread the oil/wax.

This was the last process, I needed to add a wax or oil finish so the wooden features of the chair can be seen. I used teak oil for the colour and water resistance when used outdoors. I had to use a cloth and wet it so I can apply the wax to the chair. I had to also ensure that I didn’t get any wax on the flexi plywood because my design only consists the frame of the chair being waxed.

You can place the chair in the garden and relax in the sun!