CABO LOUNGE

Seeking material innovation, The Cabo lounge chair showcases the use of carbon fiber, creating an ultra-lightweight structure with outstanding strength and ergonomic comfort. Its minimalist design, inspired by the fluidity of coastal curves, blends effortlessly into modern interiors, offering both elegance and functionality.

IDEATION

focused on exploring MATERIALITy, IDEATING THROUGH sketching, prototyping, and 3D modeling. balancing durability, comfort, and aesthetics

FABRICATION PROCESS

MOLD

I utilized Fusion 360 to design a precise positive model of the seat pan, which I then segmented into ten individual layers, each one inch thick, for CNC machining. After machining, I meticulously assembled the mold pieces through a detailed process of gluing, sanding, and applying Bondo to achieve a seamless surface.

The next phase involved carefully applying multiple layers of primer, with each coat being sanded and refined with additional Bondo as needed. This cycle of priming, sanding, and smoothing was repeated over the course of eight layers, ensuring a flawless finish.

LEG JOINT

To further refine my CNC machining skills, I executed the leg joint through a multi-step process involving precise programming for aluminum and a strategic part flip.

The process began with machining the first side of the joint, followed by creating a buck from rem board based on this negative. This buck enabled an accurate flip within the machine, allowing for the removal of excess material and completion of the joint.

LEG FIXTURE

At this stage of the build, with the individual components complete, the challenge shifted to designing a fixture that would precisely align and rotate the legs into their required positions.

I engineered a false floor to accurately mimic the placement of the legs and joints, ensuring the aluminum joints could be epoxied securely in place. Once the joints were properly aligned, the final layers of carbon fiber were applied, completing the structure and preparing the chair for final assembly.

FINISHING

The final steps involved meticulously applying multiple coats of clear finish to the carbon fiber, with each coat followed by wet sanding to achieve a high-gloss surface. Simultaneously, I carefully brushed the aluminum legs to enhance their appearance, giving them a sleek and refined finish.

Once both elements were perfected, I assembled the chair by fastening the aluminum legs to the seat pan, allowing me to finally see the entire piece come together!