Chair project: Designed for the future
Words and photos: Wei Wu
Illustrations: Graham Sands
From a young age, I always wanted to do something out of the box and creative. This passion led me into a very fulfilling career in industrial design that went for more than two decades. I was very fortunate to receive worldwide recognition and awards, which drove me to keep pushing the boundaries of creativity. It was on this incredible journey that I gradually came to understand how profound an impact design can have on our world.
Whereas good and conscientious design elevates our lives, there can be a dark side as well, especially when products are designed to merely prioritise profit over people and planet. My heart couldn’t help sinking when I saw fast fashion products and gadgets everywhere in the world, depleting our natural resources and contributing to mounting waste.
I asked myself how I could design and create something beautiful, thoughtful, and durable that people will like and cherish for generations. Then the opportunity arose when my daughter came into this world as a gift to me.
As she began to grow, I realised that there wasn’t any furniture out there that ticked all my boxes: child-friendly, safe, cosy, stylish and sturdy... I couldn’t find anything on the market that I wanted to buy for my daughter, something she might want to keep and use throughout her life, just like my grandmother had an old wooden chest that was passed down from her father.
That realisation led me to my very first step into the wood industry, and eventually shifted my focus to creating long-lasting items.
In the beginning
I started by crafting a solid wood chair for her. The chairs on market were either too light and unstable for a lively child or didn’t meet my design standards or weren’t likely to be suitable as she grew bigger.
Thoughtful design is always my priority. Key criteria such as universal appeal, natural beauty, sustainability, and being eco-friendly immediately come to mind. Despite being new to the woodworking industry, the journey of creating this chair was a blend of challenge and fulfillment. Hours of research went into identifying the best wood types, mastering various joinery methods, and perfecting the design for aesthetic appeal and functionality. Each phase of the process was a labour of passion, from hand-picking the wood to applying the final coat of plant-based oil. With careful attention to every little thing, I wanted to make sure this chair would be my child’s timeless favourite, something she would love for a long time.
Design
Photo 1: A good design initially starts with a simple idea. Apart from the actual making, the design will have a decisive role in the quality of the work. Having design background is helpful for handcrafts, but if you haven’t been trained in design or drawing you need not worry, because handcrafts are the window to conveying human spirit. As long as you concentrate your mind, you can surely make a work that touches people’s hearts.
Preparing the wood
Photo 2: According to the original design intention, this is a child's chair for a little girl, so I chose hard maple wood with fine grain and light colour. Except for the seat panel, the rest of the parts need 50mm thick sections which were machined on the planer, thicknesser and tablesaw.
Fig.1 shows the parts and how they are joined.
Make the mortise and tenon
Photo 3: Mark out the tenons, remembering that the back legs are at an angle (fig.2).
Photo 4: Cut along the marked lines with a bandsaw, or with a hand saw if it is not convenient to use machinery or power tools.
Making the backrest
Photo 5: I used the bandsaw to cut the arch for the top rail of the backrest.
Photo 6: A spokeshave allowed me to smooth the curved surface after bandsawing the cut.
Photo 7: Use the drill press to make the holes for the backrest supports.
Photo 8: For the straight sided mortises, first drill holes then use a chisel to clean out the waste.
The seat
Photo 9: Rebates are routed onto the edges of the seat panel, then a dovetail router bit is used to run a dovetail groove in the centre of the panel underside.
Photo 10: Insert the prepared reinforcement into the dovetail groove in the seat panel.
Rounding components
Photo 11: I wanted to soften all the edges of the chair, so after the joinery was cut I rounded over the long edges of all the different parts with a round over bit.
Photo 12: Grooves to accept the seat panel were routed into the seat frame and in the legs for attaching to the seat panel.
Assembly sequence
Photo 13: The seat panel is first fitted to the front and rear frames.
Photo 14: The side frames are then attached before attaching them to the seat.
Photo 15: Next, insert the backrest supports into the holes in the rear of the chair frame. Lastly, fit the top crest onto the supports.
Photo 16: After a test dry fit, get everything ready to then apply glue and clamp all joints up securely.
Rounding corners
Photo 17: The design of this piece features large rounded transitions at all curves, most joints can only be processed by hand and this part will test one’s patience. I used an angle grinder with sanding discs to progressively sand from coarse to fine, constantly feeling the piece to achieve the final shape I was after.
Finishing
Photo 18: I wanted a natural finish that could easily be replenished from time to time. A paste wax was chosen and three coats applied sanding lightly with 320 grit paper between each.
The result was a smooth well finished with surfaces that were pleasing touch and user-friendly for a small child.
Looking back
When the chair was finally finished, it was everything I had hoped for and more. It was sturdy and beautiful, with a natural finish that highlighted the wood grain and knots. It was solid and stable, with a generously sized seat so that even as my children grew, it would still be perfect for them to sit on.
More than a decade has passed ever since I first made this chair, yet it remains a beloved fixture in our home. My daughter still sits happily on it. Even some elderly family members and friends loved the chair. I couldn’t help but marvel at the journey it represented. From a simple idea to a tangible piece of work, it felt so good to know that I had created something for all ages, something that would last for many years, something that my children could pass down to their own children someday.
Now this chair has become more than just a piece of furniture in our home. It is a symbol of the values I hold dear and the lessons I hope to impart to my children. It stands as a reminder of the importance of sustainability, quality, and the need to cherish what we have. By creating this chair, I have not only provided my children with a beautiful and functional piece of furniture but also with a legacy that will hopefully inspire them to make mindful choices throughout their lives to protect our environment and appreciate the things we have.
This chair, born out of a wish to make a difference, is a small but pivotal step towards my passion and journey in wood and my dedication to designing for a more sustainable future.
First published in Australian Wood Review issue 125, September 2024
Wei Wu @_woodway_ was Maker of the Year Overall Winner 2023. He is based in Melbourne and works in wood and other creative mediums. Learn more at https://woodway.com.au/