Last year, we became enamored with the Cartesian Chair we spotted during NYCxDesign week. Designer Alexander Purcell Rodrigues worked with aluminum manufacturer Neal Feay to achieve new, cutting edge aluminum fabrication techniques along with generative CAD modeling tools to push the “structural limits and precision machinability” of aluminum. The results are a chair with a sleek silhouette that’s truly a work of art. Each chair is made from aircraft-grade aluminum with an ombre anodized finish or with solid wood legs. While the chair looks like it’s been milled from a solid block, they’re actually fabricated from small stock which keeps waste to an absolute minimum. Take a closer look to see how this exquisite chair is made in this month’s Deconstruction.

How the Cartesian Chair is Made in main home furnishings  Category

Initial sketches.

How the Cartesian Chair is Made in main home furnishings  Category

First sit prototype.

How the Cartesian Chair is Made in main home furnishings  Category

Grasshopper chain created to turn mathematical equations into the patterns that will be mapped to the backrest and leg surfaces, thereby creating machinable ornamentation.

How the Cartesian Chair is Made in main home furnishings  Category

Ornamentation ideation created by numerous algorithms.

How the Cartesian Chair is Made in main home furnishings  Category

Early pattern and anodize test samples.

How the Cartesian Chair is Made in main home furnishings  Category

Ornamentation mapped to the backrest surface. Backrest seen here located on the jig to allow for accurate locating within three diminutional space.

How the Cartesian Chair is Made in main home furnishings  Category

Computer generated pattern testing.

How the Cartesian Chair is Made in main home furnishings  Category

Full size back and leg interface samples to ensure pattern is mapping accurately.

How the Cartesian Chair is Made in main home furnishings  Category

Legs being milled.

How the Cartesian Chair is Made in main home furnishings  Category

Brushing process achieved with a steady hand.

How the Cartesian Chair is Made in main home furnishings  Category

Forming of the backrest.

How the Cartesian Chair is Made in main home furnishings  Category

Backrest aligned on jig entering the 4 axis mill.

How the Cartesian Chair is Made in main home furnishings  Category

Ornamented backrest ready for finishing.

How the Cartesian Chair is Made in main home furnishings  Category

Early stages in the anodizing procedure. A 6-step process through 12 different tanks.

How the Cartesian Chair is Made in main home furnishings  Category

Chair in its flat-packable form for a lower cost greener distribution foot print.

How the Cartesian Chair is Made in main home furnishings  Category

Three of the finished versions: Ornamented and upholstered with ombre anodize finish / Pure aluminum version with ombre anodize / White oak with natural anodize.

How the Cartesian Chair is Made in main home furnishings  Category

How the Cartesian Chair is Made in main home furnishings  Category

How the Cartesian Chair is Made in main home furnishings  Category