well proven chair by marjan van aubel + james shaw

through the understanding that there is 50% to 80% of timber wastage during manufacturing, london-based designers marjan van aubel and james shaw have investigated ways of incorporating waste shavings into design using bio-resin. a curious chemical reaction occurs when they are mixed with the scraps, expanding it into foam. the reaction is exacerbated by different types of wood, the addition of water, air trapped in material, and increased temperatures these different factors can give expansion of up to 600-700%.

the well proven chair
all images © petr krejci / courtesy of marjan van aubel

by adding color dye and varied-sized shavings from different workshop machines, a colorful, lightweight and moldable material is created, reinforced by the fibers in the hardwood discards. a porridge-like mixture the formed material is slapped on to the underside of the chair shell by hand, building up the material wherever extra strength was required. the mixture then foamed explosively to create its own exuberant form, anchored by the simple turned legs of american ash.

detail of the expanded material

the well proven chair in a red and green color variation

finished chair in the studio

troubleshooting after releasing the chair from the mould

finishing detail process

applying thin layers of the material onto a mold

batches of the material mixture

scrap wood for the mixture

expanded foam tests and samples

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