CLICK HERE FOR INDEX PAGE | |||
BASIC MANUFACTURING OF THE EAMES LOUNGE CHAIR ALUMINIUM PARTS / COMPONENTS |
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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. |
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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. | ||
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 | |||
CLICK HERE FOR PRODUCT DESIGN INDEX PAGE | |||
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