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Exploration 1
Exploration 2
Unframed Thinking: Yves Béhar talks about the idea of life unframed.
Exploration 4
Exploration 5
Meeting of the Minds: Jack Schreur, Herman Miller’s “Chief of Chairs” and Yves discuss “How big is the challenge?”
Exploration 6
Inspiration: A simple question at the fuseproject SF studio.
Exploration 7
Stop Motion Fun: A trail of sketches leads through the studio.
Exploration 8
Material Studies: From woven textiles to die-cut expanded EVA to molded and stretched polymers, a broad range of materials and production techniques were tried.
Exploration 9
Preliminary Ergo Study: The team maps key support zones for people of different height and size.
Exploration 10
Exploration 11
Smart Support: How can we provide support and flexibility with a minimum of material?
Exploration 12
String Theory: Yves and Bret Recor, of fuseproject, work with an early suspension back prototype.
Exploration 13
3D Support: Scanned data points from the string prototype are matched with ideal ergonomics.
Exploration 14
D.I. PLY: Making proto chair parts and stretching elastic strands to test feel and comfort.
Exploration 15
Finding the Right Fit: Yves works with the team to evaluate an early prototype.
Exploration 16
Fail Faster: Many suspension back prototypes, used to quickly evaluate forms, material approach, comfort, and ergonomics.
Exploration 17
Sitting Is Believing: Trying out the early prototypes.
Exploration 18
Drawing It Old School: Suspension back pattern concepts were meticulously drawn with pencil and trace.
Exploration 19
1:1: One of a hundred full-scale sketches of proposed flexible polymer suspension back pinned up.
Exploration 20
Pattern Exploration: Hand-drawn explorations of geometric, organic, woven and linear suspension patterns.
Exploration 21
Drawings in Stop Motion: Sketches refine the initial concept and fill up the studio walls.
Exploration 22
Marigold Lodge in Winter: Yves and the designers split their time between the fuseproject studio in SF and Herman Miller HQ in Michigan.
Exploration 23
Finding the Ideal Tension: Herman Miller engineers experiment with various attachment methods for the suspension back.
Exploration 24
Long Hours: Need we say more?
Exploration 25
Design Review: Sharing the initial concept prototypes with the Herman Miller executive team.
Exploration 26
Exploration 27
Function over Form: fuseproject designers and HM engineers evaluate stretched sail protos using a simple steel and wood version of the Y–Tower.
Exploration 28
First Suspension Materials: Patterns are die-cut from flat elastomer sheets for testing before moving to 3-dimensional molded parts.
Exploration 30
Quest for Comfort: A wide range of materials and textures are evaluated to combine support and flexibility.
Exploration 31
Calipers and Coffee: On-the-fly sketches to refine attachment points to the seat arm and boom.
Exploration 32
Ergonomic Studies Bear Fruit: By varying the thickness and grid spacing of the suspension back, targeted support and flexibility to the lumbar and spine is achieved.
Exploration 33
Triangulation: Combining the arm supports and boom into a singular triangulated structural piece reduces material use, increases overall strength, and visually lightens the chair aesthetics.
Exploration 34
Do Over: Sometimes even the best design intentions don’t yield results… only option: start again.
Exploration 35
Eco-Dematerialization: Through design iteration, we reduced material use (and environmental footprint), without sacrificing durability or comfort.
Exploration 36
Y-Tower Optimization: The structural mast supporting the suspension back was strategically carved away to maximize strength and minimize material use.
Exploration 37
Smart Structure: Even the base of the chair was dematerialized, optimizing the design for strength, weight and sustainability.
Exploration 38
Evolution of an Idea: Sketches trace the evolution of the SAYL chair family from concept to completion.
Exploration 39
Exploration 40
Inspecting the Goods: First suspension backs come out of the mold.
Exploration 41
Inspecting the Machine: The correct pressure and material flow can only be achieved through perfect tool alignment.
Exploration 42
Supergrid: Closer look at the injection tool.
Exploration 43
Production Test: The first elastomer suspension back parts are run on the line.
Exploration 44
Shop Talk: Bob, Brian and Bret’s production logistics discussion in the Greenhouse assembly line in Michigan.
Exploration 45
Rough Treatment: A 200-pound seat drop and repetitive seat recline test to ensure decades of use and the full 12-year warranty.
Exploration 46
Stop-Motion Refinements: Finalized details in sketches, CAD and prototypes.
Exploration 47
Creating a Family: Adapting the task chair design and patents to side chairs, in wire sketches.
Exploration 48
Side Chair Skeleton: Prototype of the side chair in the fuseproject studio.
Exploration 49
Side Chair Evolution: Full-size working models of the SAYL family side chairs.
Exploration 50
Weight Testing: A 300-pound weight is drop tested on the cantiliver chair…big smiles when the test is a success.
Exploration 51
Anticipation: A veiled prototype of the SAYL chair sits in the Herman Miller studio.
Exploration 52
Color Wall: Yves in the Herman Miller material library, finalizing fabrics for the SAYL family.
Exploration 53
First Assembly: Initial prototype run in the factory.
Exploration 54
Shadow Play: Light shining through the suspension back pattern….
Exploration 55
Ready for SAYL’s Close-Up: An early photoshoot in the fuseproject studio.
Exploration 56
The Beauty is in the Details: Sculptural armrests line up.
Exploration 57
Family Portrait
Exploration 58