Behind the Scenes: Making the Aspen Lounge Chair

The Aspen Lounge Chair is more than just seating, it’s a symbol of thoughtful design and enduring craftsmanship. Its clean lines and inviting comfort may feel effortless in your home, but behind every chair is a long process of precise handwork and careful attention to detail. Step inside the workshop, and you’ll see how raw materials are transformed into a piece that blends form and function seamlessly.

The journey begins with the cushions, the foundation of comfort. High-density foam is cut, layered, and shaped to fit the body’s natural curves. This isn’t a matter of stacking blocks of material; each piece is crafted to strike the perfect balance between support and softness, ensuring the chair remains comfortable for years of use.

Precision cutting is the next stage. Using specialized tools, artisans trace and carve each section of foam so that when upholstered, the fit is seamless. This step ensures that every cushion sits snugly in place, with smooth contours that reflect both design intent and ergonomic function.

Then comes the leather. Each hide is inspected and carefully marked, with patterns traced by hand to maximize both strength and beauty. By aligning the natural grain and selecting only the finest cuts, the finished upholstery has a consistent look and feel. This attention to detail ensures the Aspen doesn’t just look refined, it feels luxurious to the touch.

Meanwhile, the molded wood shell — perhaps the most iconic feature of the Aspen — takes shape. Thin layers of plywood are sorted, stacked, and prepared for pressing. Each layer is chosen for grain consistency and strength, setting the foundation for durability.

The veneers are carefully stacked and then pressed together under heat and pressure, a process that fuses the layers into a single, strong form. This is where the Aspen’s signature curves are born — not bent in a rush, but shaped slowly and evenly so the wood retains both its strength and its graceful lines. It is a balance of engineering and artistry, ensuring the shells are as resilient as they are elegant.

Once the press releases and the curves take shape, each shell undergoes trimming to refine the edges and ensure exact dimensions. From there, every piece is meticulously inspected, with craftspeople checking for consistency, strength, and surface quality. Only after these steps are complete does the shell move forward to finishing, carrying with it the assurance that it meets the high standards required to become part of the chair’s iconic silhouette.

Once the plywood layers are pressed into shape, the shells move on to precision cutting. Using advanced machinery, the curved forms are trimmed and refined to exact dimensions. This stage ensures that every piece matches the design specifications down to the millimeter, preparing the shells for the hand-finishing that follows. It’s a moment where technology meets craftsmanship: machines provide accuracy, but the process is guided and overseen by skilled workers who know how to bring out the best in each panel.

Sanding smooths the surface, not only preparing it for veneer but also ensuring that every edge feels flawless. This step is carried out by hand, emphasizing a tactile quality that machines alone can’t replicate.

Finally, the wood is primed and finished. Layers of lacquer bring out the natural character of the grain while adding protection. This is where the shells gain their warm glow, a finish designed to stand the test of time.

In the upholstery workshop, the chair comes together. Leather is stretched and stitched over the foam and wooden shells, with each seam and contour adjusted by hand. The work is painstaking, but the result is unmistakable: smooth lines, perfect tension, and a seat that feels as good as it looks.

From raw materials to finished form, the Aspen Lounge Chair is a story of transformation. Every stage — foam cutting, leather tracing, wood pressing, sanding, and upholstery — reflects a blend of modern techniques and traditional craftsmanship. The result is not just a piece of furniture, but an enduring design that carries the mark of the many skilled hands behind it.