Solutions: Aeron Chair Arms

Aeron Chair

Aeron Chair

The Challenge

Herman Miller’s Aeron chair is a legend, as is the company’s commitment to environmental sustainability. From a green perspective, however, the chair’s armrests were a weak point. Herman Miller asked us to propose a cost competitive, locally produced environmentally friendly alternative to injection molded PVC.

Our Solution

Working with Intex, Royal Technologies developed an armrest from a self-skinning polyurethane foam, eliminating the use of PVC entirely while at the same time simplifying production and cutting both the cost and weight of the finished component by roughly 20%.


Aeron Chair Achieves MBDC Silver Certification

Herman Miller, Inc., is again demonstrating its commitment to environmental sustainability with one of its most iconic and successful seating designs--the Aeron chair.... This renowned design now further distinguishes itself by receiving McDonough Braungart Design Chemistry (MBDC) Cradle to Cradle Silver certification for environmentally friendly design. "In Aeron's case, we particularly addressed the use of PVC in the arm pads. After significant research and collaboration with a new, minority-owned supplier, our ambition for a PVC-free, polyurethane arm pad is now a reality." 

Technical Details

Previous Situation Our Solution Downloads

Previous Situation

  • Injection molded PVC skin.
  • PU foam molded around High Impact Nylon.
  • Multiple staples to secure skin to foam.
  • Environmentally unfriendly due to PVC.

Our Solutions

  • Integral skin PU foam
  • In-mold coating
  • 100% Post Industrial Regrind Nylon used for the insert.
  • Eliminated all post assembly operations (no need for any staples)

Solution Benefits

Browse More Solutions

F250 Seat Composite Cushion Frame

Ford F250

A plastic alternative at a lower cost point with greater flexibility

Precision Optics

Precision Optics

One of our customers asked us to help make their automotive safety lenses even more precise.

Zody Chair Back Assembly

Zody Chair

Taking a prototype design for a revolutionary new task chair and making it production-ready.

Automotive Side Shield

Side Shield Front

Creating a less expensive, easier to produce, and more flexible automotive side shield.

Cut TDI to Molded MDI Foam

Foam Production

Taking a complex cushion and making it simple, less costly and more comfortable.

Aeron Chair Arms

Aeron Chair

Developing an environmental-friendly, low-cost, light-weight arm rest for a world-renowned product.

File Compressor Conversion

Plastic can offer several advantages of steel with none of the disadvantages

Our file compressor weighed less than 30% of the original and costs 30% less.

Arm Assembly Redesigned

Redesigned Arm

Lowering production costs by nearly 15% while improving product strength and ease of assembly.