Our M+M (Methods + Materials)

The Function (Fn) of our products is key. Our furniture parts nest like puzzle pieces to use every inch of our materials. The shapes are body-fit, the build is sturdy, and the fabrication is local. 

Efficiency

Our furniture is carefully designed so 0 to 0.06 is left over of each sheet of plywood or weatherproof HDPE.

Assembly

We keep it simple, with few parts and few fasteners. For example, our outdoor lounge has eight parts while the closest ones on the market are 18 to 40 parts. Most of our furniture ships flat, slots together, and tightens up with hidden fasteners. The fasteners are already installed, so there is no bag of loose hardware.

Sturdiness

Few parts also lead to super strength. Usually, fasteners tire out or furniture fails at the joints, like where legs meet aprons. In our furniture, the plywood or plastic continues uncut through these vulnerable spots, reinforced at right angles by more continuous material. In addition, the designs send normal loads from plywood to plywood (or plastic to plastic) which compresses the fasteners without stressing them.

CNC

Computer Numerically Controlled (CNC) router tables are becoming common in cabinet shops worldwide. Mostly, the shops use them to make quick, rectangular cabinet parts.  For us, the shops make the exacting parts and joints of our furniture. The speed and accuracy enable efficient, cost-effective production.  

Outdoor Plastic

Our outdoor furniture is made from a marine-grade high-density polyethylene (HDPE) sheet. It has a matte finish on both sides of the sheet. It is environmentally stabilized to withstand the harshest outdoor conditions. It will not rust, delaminate or rot when exposed to UV, humidity or water. The polymer sheet is durable and colorfast and never needs painting or refinishing. The color goes all the way through, so scratches only appear as changes in texture.

The sheets are environmentally sound. They can even gain LEED credits. The fabricator uses processes that are non-polluting, conserve energy and natural resources. The polymers are completely recyclable and the fabricator recycles material waste back into their products. When cutting or fabricating, there is no harmful dust, but instead small shavings that can be recycled. It contains no known harmful substances including carcinogens or toxins so it’s safe for employees, communities and consumers. It does not off-gas when the sheets are cut and fabricated. If the product is burned (but don’t!), there are no harmful gasses emitted. It is not necessary to use acids or harsh chemicals for cleaning and maintenance. The recycling grinders that can handle these thick sheets are not common enough yet, but the outstanding durability maximizes product life cycles, thus reducing the overall impact on our environment.

Plywood

Plywood is made from thin tree peelings. It uses less glue than other composites and feels better. It is more stable than regular wood because the grains are crossed and glued to reinforce one another.  

We use a multi-layered Baltic Birch Plywood.  The extra layers make the boards extra stable and the edges extra handsome. It passes CARB II emission standards for Formaldehyde (California 93120 Phase 2 compliant for formaldehyde), the strictest emission standard to date.

Colored Plywood

Our colored plywood comes from Finland where birch trees grow dense and slow and plywood has been made well and sustainably since the 1930’s. Both sides of the board are coated with a colored translucent phenolic film that is suitable for food products, smooth, easy to keep clean, and leaves the wood grain visible. Wood species used are certified according to PEFC and FSC Chain Custody and certified ISO 9001 and environmental ISO 14001 Management system.

UV Cured Acrylic Finish

Our clear sheets are finished with 100% acrylic cured by UV light. Light cured finish has been used since the 70's. Unlike other finishes, no solvents are needed to help it dry, so nothing evaporates into the atmosphere. It contains no Volatile Organic Compounds (VOC’s) or Hazardous Air Pollutants (HAPS.) The finish needs to be evenly exposed to the light, so it works best on flat surfaces.  Our furniture starts out flat, so it’s perfect for us. 

  • The acrylic cures very hard and is solvent and scratch resistant. It does require some care because if it gets damaged, invisible repairs are difficult. 

  • Acrylic does not yellow, though the plywood may naturally bronze with age.  

  • UV bulbs now replace standard bulbs in the process. They last longer, conserve energy, don’t need to heat up, and don’t heat the plywood or the finishing room.

  • The finish cures immediately.

  • Any overspray that is not exposed to the UV light can be reclaimed, so waste can be almost completely eliminated.  

Plywood Edge Seal

We use Tried and True Wood Finish to seal the edges of the plywood. Adapted from a Shaker recipe, it’s made from a highly refined polymerized linseed oil with pure beeswax as an additive. It contain no petroleum distillates, no solvents and no heavy metal drier additives. It strictly adheres to the standards established by the FDA (Food and Drug Administration) and qualifies as non-toxic and safe for food-contact surfaces in both its uncured and cured (wet and dry) states.