Molded plywood chairs, known for their elegant curves and strength, are primarily made by shaping thin sheets of wood veneer using heat and pressure with a special resin.
The Molded Plywood Process
Manufacturing molded plywood chairs involves a precise technique to transform flat veneer sheets into durable, curved forms. Based on the provided information, this process relies on molding multiple layers of veneer together.
Key Steps in Molding Plywood Chairs
The creation of a molded plywood chair part, such as a seat or leg, follows specific steps:
- Layering Veneer Sheets: Thin sheets of wood veneer are carefully layered. The number of sheets varies depending on the structural requirement of the part. For instance, the reference states that seat and back components are molded from five sheets, while the legs and spine components utilize nine sheets.
- Applying Resin: A thermosetting resin is applied between the layers of veneer. This resin acts as a bonding agent that, when heated and cured, creates a strong, rigid bond holding the layers together in their molded shape.
- Molding with Heat and Pressure: The layered veneers and resin are placed between heated platens. These platens are specially shaped molds that apply significant heat and pressure. The heat activates the thermosetting resin, and the pressure forces the veneer layers to conform to the mold's curvature while the resin cures, bonding them into a single, solid piece in the desired chair shape.
Finishing the Surface
After the molding process, a finishing step is typically applied:
- An impregnating resin is sprayed on the surface of the veneer.
- This resin is then cured against the platen during the molding process itself, resulting in a smooth, durable surface finish integral to the plywood layer.
This method of molding and finishing simultaneously allows for efficient production of curved, strong, and aesthetically pleasing chair components.
Understanding the Materials
- Veneer: These are very thin slices of wood, allowing flexibility and the creation of curved shapes when layered.
- Thermosetting Resin: A type of plastic resin that hardens permanently when heated, providing the strong bond between veneer layers that gives molded plywood its structural integrity.
- Heated Platens: These are the heated plates of the press that provide the heat and pressure necessary to shape and cure the layered veneer and resin into the desired chair component.
Using this process, individual parts like seats, backs, legs, and spines are created and then assembled to form the complete molded plywood chair.
