Solutions: Zody Chair Back Assembly

Zody Chair

Zody Chair

The Challenge

Good design is integral to the furniture industry—not only in appearance, but structurally as well. One client asked us to take their prototype design for a revolutionary new task chair and make it production-ready.

Our Solution

The final design weighed less than 30% of the original while maintaining all of its original functionality. In addition, we were able to lower the cost by roughly 30% and improve the piece’s overall aesthetics.

Technical Details

Initial Concept Design Our Solution Downloads

Initial Concept Design

  • 2 piece structural frame
  • Flexible ring sewn to fabric
  • Ring / Fabric sub-assembly manually tucked into frame groove
  • Visible mechanical fasteners attaching upright to frame

Our Solution

  • Mesh fabric ultrasonically bonded to inner frame
  • Inner frame/fabric are welded to outer frame
  • Unique and patented back assembly process
  • No visible fasteners
  • Variable tension in different zones of back

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.