Aero Chair
Vertex Furniture
Client
Vertex Furniture
Year
2024
Services
Industrial Design, Manufacturing Management
Materials
Recycled Aluminum, Ocean Plastic Mesh, FSC Plywood
Overview
The Aero Chair proves that sustainability and ergonomic excellence aren't mutually exclusive. Every component — from the recycled aluminum frame to the ocean-plastic mesh — was engineered for a 15-year service life. We handled the complete product lifecycle: research, design, prototyping, and manufacturing coordination across three continents.
Challenge
Recycled materials introduce variability in structural properties. The chair needed to meet BIFMA X5.1 standards while using post-consumer materials that don't behave identically batch to batch. The client also required a retail price under $800 — aggressive for a chair of this specification.
Approach
We developed a parametric frame design that compensates for material variability through geometry rather than material spec. Finite element analysis validated 47 load scenarios across the expected material property range. Manufacturing was split strategically: structural components in Germany for precision, upholstery in Portugal for craftsmanship, final assembly in the target market to reduce shipping.
Outcome
The Aero Chair passed BIFMA certification on the first submission and launched at $749. It won a Red Dot Design Award and has sold 30K units in its first year. The recycled material supply chain we established has been adopted for three additional products in the client's lineup.
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