Delicious Design Process: Steelcase Leap Chair Gets 3D, Fabbing and More

I didn’t get to try out the Embody Chair, but I’ve been living in a Steelcase Leap Chair for the past month. It’s been a… different experience I’ll tell you all about in an upcoming post.

In the meantime, feast your taste buds on this. I had the chance to also ask the design team at Steelcase about the design process behind the Leap chair. An ensuing mountain of information about all that went into creating this fabulously ergonomic bucket-for-yer-butt.

Check it out and tell me if it doesn’t leave you the least bit inspired.

What tools/programs (sketching, 3d CAD, simulation, rendering?) were used in the design process of the chair?
The Steelcase Design Studio and the design consultant that Steelcase with on the Leap Chair design used hand sketching, Graphite and Vectorworks 2D drawing programs, Rhino and ultimately ProE to develop ideas in virtual 3D, renderings are of some value and we use the capability embedded within Steelcase’s 3D programs for this purpose. Steelcase’s most valuable tool for testing and validating design concepts is physical modeling. To see a chair in full scale, in detail as a real three dimensional object, to walk around it and touch it… is the ultimate test. Chairs are physical, sculptural, functional objects.

How many iterations did the chair go through in engineering it?
In the development process it is likely that any chair will see dozens of full visual models, and roughly the same count of functional ‘works like’ models. Ultimately the iterations are impossible to count. By the time Steelcase is closing on final engineering drawings ready for tool release that it has made literally hundreds of subtle changes addressing and testing learnings made through development. FDM (Fused Deposition Modeling) prototypes were used extensively in engineering for functional evaluation. Urethane Casting was used for large functional parts. Almost every plastic part had a 1-cavity rapid prototype tool built that we ran out at the PRC to make our development parts. 6-axis laser trimming was used to trim the edges of prototype stamped parts

What aspects of the project (concept, prototyping, rendering) revealed the vision behind the chair?
Functionally, Steelcase’s vision was to address ergonomic advantages for vision, reach and spinal performance. The story is most clear in printed media and the product satisfies user need for this very functional performance. Additionally, Steelcase aspired to render an object that communicates a sensual sophistication, a subtle athleticism, and technical merit speaking to the potential of the Leap Chair capability. Ultimately, the promise and the perception of the chair was tested in concept through physical modeling where Steelcase (design and engineering) could assess the strength of the ideas. Additionally, Steelcase used both physical and virtual tools to test ideas in formal market validation with customers and dealers.

Was any rapid prototyping used in the development of the chair?
SLA, 5 Axis routing/milling was used to construct physical models.

CAD users sit for hours in chairs. What is the greatest benefit for them by using this chair?
It’s a high performance task chair. It is capable of supporting users in a proven healthy manner (SEE CASE STUDY ATTACHED AND Leap Mini site on www.steelcase.com/Leap ) for extended periods of time while working at a computer. People are designed to move and the chair accommodates this while helping users maintain correct focal length with the display. As users recline to redistribute physical pressure through the back and the seat we’ve designed a solution to help them stay engaged with the keyboard. The mechanics of ‘Natural Glide’ are key to Leap and the ‘Live Back’ further encourage movement in the spine which is key to spinal health.

How did the chair design/engineering benefit from the 3D CAD and rapid prototyping (if used)?
The benefits of using 3D CAD and rapid prototyping were speed and accuracy. Steelcase was able to process decisions faster and with more confidence. Database’s could be tested with greater resolve and ultimately, when it came time to build final (and very expensive) tools, Steelcase was able to check data and release with total confidence that what we see is what we would get.

Other Cool Facts About the Chair

• The technology in the Leap extends through the company’s seating portfolio and has been integrated (in some way) in virtually every chair launched by Steelcase since Leap (e.g. Think, Amia, Move, Siento, cobi and i2i). It has also been licensed for use in automobiles and airplanes by those industries respectively. The Leap technology is currently being used by Cathay Pacific and Japan Airlines with other airlines close to announcing their plans to integrate as well.
• Leap was four years in development; the company partnered with four universities, 27 different scientists and 11 studies including 732 participants
• When under development, the Steelcase seating development team took a fresh look at biomechanics and the impact increased computer use was having on workers who could be tethered to their computers for up to nine years of their life.
• LiveBack technology allows the upper and lower parts of the backrest to function independently.
• Leap mimics the individual user’s unique spinal motion so the user is free to move, but never left unsupported, allowing the user to stay comfortable and productive.
• Lower back controls allow the user to specify the preferred amount of lumbar support, creating a hugging sensation as the pressure is dialed up.
• The Natural Glide System allows the seat to glide forward so users stay in the vision and reach zone even when reclined

Wow, that’s a design process. Not that it’s any less than what most of us designers and engineers go through daily, but inspiring nonetheless.

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