Moulded Plywood Lounge Chair Shell
A one-piece moulded seat shell with continuous curvature, pressed rather than cut from flat sheet.
A lounge chair shell is the single largest formed surface on the chair, and it decides whether the chair reads as comfortable or as injection moulded. We press it in matched male and female moulds so the compound curve runs continuously from the front edge into the back rise, with no flat spot and no seam line.
Quick Specifications
| Material | Birch or mixed-core laminated plywood |
|---|---|
| Typical lay-up | 9 to 15 plies, cross-banded |
| Shell thickness | 9 – 15 mm |
| Moulded depth | 380 – 480 mm |
| Width | 420 – 700 mm |
| Bend form | Press-moulded compound curve, radius 5:1 – 8:1 |
| Surface | Clear lacquer, PU lacquer or stain to colour |
| Overall tolerance | ±0.5 mm on machined reference faces |
Why press-mould the shell
A moulded shell has no flat reference panel, so it resists the racking that makes multi-piece seats loosen after a season of use. Because the grain is not cut across a curve, there are no stress concentrations to crack, and the whole surface takes a finish evenly.
How the curve is formed
Veneer is laid up, glued and cured in a heated press. For compound curves we use matched moulds, which hold the three-dimensional shape while the adhesive cures so the shell arrives at your line ready for assembly with no secondary forming.
What we need from you
A drawing showing width, moulded depth, thickness, surface finish and any reference features such as hinge or fixing holes. If you only have a sample, send it and we will reverse engineer the tooling from it.
Request a quote
Send your drawing, sample or dimensions and we will confirm feasibility, tooling, MOQ and lead time. Prototypes typically run 7-15 days and production orders 15-30 days.
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