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BASIC MANUFACTURING OF THE EAMES LOUNGE CHAIR
ALUMINIUM PARTS / COMPONENTS

V. Ryan 2011

 

 
The main parts / components of the chair are the cast aluminium base and frame/support and the plywood / veneer forms, including the head rest, back rest and seat.

The aluminium parts are cast from aluminium ingots and recycled aluminium.

The plywood / laminated forms are manufactured through steam bending of the layers of veneer.
 
 
1. PREPARING THE CASTING BOXES   2. POURING THE MOLTEN ALUMIINIUM 
     
A wood pattern of the aluminium part is made. A casting box (mould) is prepared in sand, using the wooden pattern. When the sand casting box is complete, the pattern is removed, leaving a cavity in the sand

The example below shows the preparation of the casting box for the aluminium frame / support of the chair.
  A top casting box, called a ‘cope’ is placed in position. Molten aluminium is poured into the cavity left by the wooden mould. 
     
casting aluminium   casting aluminium 
 
MACHINING 
 
When cool, the aluminium castings are removed from the sand. They are finished by machines such as a vertical miller and hand tools.  A horizontal miller and shaping machine could also be used (vertical miller recommended).
 
For further information on casting and machining, click on the links below: 
 
 
CASTING ALUMINIUM 
 
Foundry Work 1 (Casting 1)
Foundry Work 2 (Casting 2) 
Foundry Work 3 (Casting 3) 
Foundry Work 4 (Casting 4) 
PDF FILE - CLICK HERE FOR PRINTABLE WORKSHEET ON THE CASTING PROCEDURE 
 
MACHINING 
 
The Vertical Miller (1) 
The Vertical Miller (2)  - Making Adjustments 
The Vertical Miller (3) - More Information 
PDF FILE - CLICK HERE FOR VERTICAL MILLER PRINTABLE WORKSHEET 
 
The Horizontal Milling Machine - 1 
The Horizontal Milling Machine - Cutters and Up-Milling - 2 
PDF FILE - CLICK HERE FOR PRINTABLE HORIZONTAL MILLING MACHINE WORKSHEET 
 
The Shaping Machine
 
 
 
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