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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.|
|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:|
|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|
|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|
|CLICK HERE FOR PRODUCT DESIGN INDEX PAGE|