How are metal chairs manufactured?

Description

Industries in the Furniture and Related Product Manufacturing subsector make furniture and related articles, such as mattresses, window blinds, cabinets, and fixtures. The processes used in the manufacture of furniture include the cutting, bending, molding, laminating, and assembly of such materials as wood, metal, glass, plastics, and rattan. However, the production process for furniture is not solely bending metal, cutting and shaping wood, or extruding and molding plastics. Design and fashion trends play an important part in the production of furniture. The integrated design of the article for both esthetic and functional qualities is also a major part of the process of manufacturing furniture. Design services may be performed by the furniture establishment's work force or may be purchased from industrial designers. Furniture may be made of any material, but the most common ones used in North America are metal and wood. Furniture manufacturing establishments may specialize in making articles primarily from one material. Some of the equipment required to make a wooden table, for example, is different from that used to make a metal one. However, furniture is usually made from several materials. A wooden table might have metal brackets, and a wooden chair a fabric or plastics seat. Therefore, in NAICS, furniture initially is classified based on the type of furniture (application for which it is designed) rather than the material used. For example, an upholstered sofa is treated as household furniture, although it may also be used in hotels or offices. When classifying furniture according to the component material from which it is made, furniture made from more than one material is classified based on the material used in the frame, or if there is no frame, the predominant component material. Upholstered household furniture (excluding kitchen and dining room chairs with upholstered seats) is classified without regard to the frame material. Kitchen or dining room chairs with upholstered seats are classified according to the frame material. Furniture may be made on a stock or custom basis and may be shipped assembled or unassembled (i.e., knockdown). The manufacture of furniture parts and frames is included in this subsector. Some of the processes used in furniture manufacturing are similar to processes that are used in other segments of manufacturing. For example, cutting and assembly occurs in the production of wood trusses that are classified in Subsector 321, Wood Product Manufacturing. However, the multiple processes that distinguish wood furniture manufacturing from wood product manufacturing warrant inclusion of wooden furniture manufacturing in the Furniture and Related Product Manufacturing subsector. Metal furniture manufacturing uses techniques that are also employed in the manufacturing of roll-formed products classified in Subsector 332, Fabricated Metal Product Manufacturing. The molding process for plastics furniture is similar to the molding of other plastics products. However, plastics furniture producing establishments tend to specialize in furniture. NAICS attempts to keep furniture manufacturing together, but there are two notable exceptions: seating for transportation equipment and laboratory and hospital furniture. These exceptions are related to that fact that some of the aspects of the production process for these products, primarily the design, are highly integrated with that of other manufactured goods, namely motor vehicles and health equipment.

Iron is the embodiment of strength and resilience, which is why it is our choice metal for many of our pieces. Few materials rival iron when it comes to forming a strong, durable base. Not only is iron a great material due to its characteristics - it can be produced in an eco-friendly and sustainable manner as well! This article covers everything about the iron we use - from the types of iron and their sources to maintenance tips for our bases.

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Why do We Use Iron for Furniture?

Iron is our choice metal for many of our pieces. This is due to the strength inherent in both cast and forged iron alongside its naturally neutral color scheme.

Strength

Cast iron is actually a carbon-iron alloy, while forged iron is made up entirely of iron. The carbon added in the cast iron process increases the molten iron's strength when cooled, while forging iron allows for the retention of the iron's natural grain structure, leading it to be a stronger material for furniture than any other alloy on the market, including bronze and aluminum alloys.

Design

Iron has a naturally cool and neutral color. This makes it incredibly versatile as the color palette matches a variety of styles. The main styles that influence our designs for iron furniture are mid century modern, rustic modern, and industrial modern, as the elements from these styles compliment the natural colors coming from the materials we use.

Types of Iron

We use two main types of iron: Cast Iron and Forged Iron. These two types differ due to their creation process.

Cast Iron

Cast Iron is a type of iron formed by pouring molten iron into a cast, letting the metal cool & harden, then extracting the cooled piece to for finishing.

Why We Use Cast Iron for Furniture

• Durable - Cast iron is the choice material for many automotive parts for a reason - it can withstand a ton of wear-and-tear.

• Tried-and-True Technique -  By using a system that has been refined by dozens of generations of craftsmen, we not only pay homage to those who came before, but also guarantee that the piece will be of the highest quality.

• Eco-Friendly & Sustainable - After sand casting, the remaining scrap can be melted for use in the creation of the next piece. This ensures that nothing goes to waste.

Creating a Pattern

The pattern is a replica of the desired end product. This is what will be placed into the sand in order to form a mold into which the molten iron will be poured. We create wood patterns, as wood is the most eco-friendly choice, but patterns can also be made of metal, plastic, or plaster.

In addition to creating an external pattern, coremaking is also necessary for pieces which are internally hollow. The core is simply sand placed within the mold in order to cast the correct internal form. Cores are typically strong yet collapsible, so they can be easily removed after casting.

Melting Metal

Unlike forged iron, cast iron is first melted prior to molding. During this process, the iron scraps are heated to their melting point until the metal is in a liquid-like state.

Forming the Mold

To create the mold, sand is first mixed with molasses in order to give the sand more structure. This sand mixture is then poured into a box frame, which will serve to contain the mold during the casting process.

Once the sand is placed in this frame, the wood pattern is placed into the sand and positioned just right in order to form the mold. Once the pattern is in the correct position, the remaining sand is poured in alongside flour and compressed in order to form the full mold.

Once this process is completed, the pattern is then carefully removed from the sand, leaving behind an imprint of the pattern within the sand, also known as the mold.

Pouring in the Metal

Before pouring in the molten iron, a gating system is set up. A gating system typically consists of a pouring cup and tunnels, or "gates", which funnel the molten iron into the mold cavity.

Once this system is set up, the molten iron is then poured into the cavity of the mold. Sand casting actually supports a variety of metals and alloys, including steel, aluminum, bronze, magnesium, zinc and tin. It can also create materials of all sizes and weights, which is why sand casting is our choice process for many of our bases.

Breaking Open the Cast

After the metal as cooled and solidified, the mold is carefully broken open to and the cast is removed. While patterns can typically be reused, the mold itself cannot.  We manually recreate the mold for every piece.

Cast Iron Finishing Process

Once the cast is extracted from the mold, it is subjecting to a finishing process. Finishing the cast iron removes the impurities from the piece and protects it from corrosion. During this process, the surface of the cast is first filed down in order to produce a smoother texture while also removing impurities in the metal.

Surface texture can be measured using RMS or Root Mean Square. RMS is the calculated root mean square average the microscopic profile peaks and valleys. A lower RMS equals a smoother surface. We typically file our iron down to be within the range of 60-300 RMS.

After filing the metal down, the piece is then either painted or sealed with a clear coat, depending on the piece. This is done in order to protect the piece, making it corrosion resistant.

Cast Iron Pros and Cons

Benefits

• Perfectly Imperfect - Since every piece is casted and finished by hand, there are minor imperfections and variations between every piece. These imperfections provide the uniqueness inherent in handcrafted items, without compromising the structural integrity of the piece.

• Rustic Result - By following traditional metallurgic methodology, our bases have just the right amount of impurities that serve to contribute to the overall rustic aesthetic of the piece. Much like metalwork found in a barn or farmhouse, our cast iron bases exude a hardy, yet welcoming charm.

• Easy Maintenance - Iron is an incredibly strong material that, when finished, is corrosion resistant and requires minimal maintenance beyond occasional dusting.

Drawbacks

• Lower Strength than Forged Iron - Since the iron is melted down and poured into a mold, the molecular structure changes. Because of this, cast iron is strong but stiff, giving it little flexibility.

  Forged iron, on the other hand, retains its original molecular structure which allows it to support more weight, since it can bend more without breaking. This isn't an issue for furniture - this difference is only noticeable when the iron is bearing a load weighing more than 3 tons. One of our cast iron tables can support the weight of a truck without an issue.

Forged Iron

Some of our other iron bases consist of iron pieces that are first forged, then welded together to form the final product. Iron forging has been around since ancient Mesopotamia, around 6,000 years ago.

Forging is the process of using heat and physical pressure in order to give form a metal into a desired shape. We typically do this by hand, using a hammer and anvil - in accordance with traditional techniques.

Why We Use Forged Iron for Furniture

• Strong, yet Flexible - 

  The forging process retains the iron's molecular structure, resulting in a piece that has superior strength when compared to casting.

• Industrial Aesthetic - Forged bases are simple and strong, which are core principles of industrial modern design. The sleek, geometric forms resulting from forging an iron base serve to complete the look of an industrial modern piece.

• Eco-Friendly - One of the hidden strengths of the forging process lies in its simplicity. Because iron forging is a relatively simple process when compared to other ironworking processes, there are less rejected products. This reduces the amount of scrap generated from the manufacturing process, which in turn reduces the amount of materials requiring disposal. This makes forged iron not only stronger than many other types of processed iron, but more eco-friendly as well.

How It's Made: Iron Forging Process

There are many different methods for forging iron. We choose to use the hot forging process. This process is relatively simple, and involves 4 main steps: Heating, Shaping, Quenching, and Finishing.

Heating

Before pressing the metal into shape, it is typically necessary to heat the metal to the point where it is malleable but not molten.

This process is accomplished by using a forge. Forges use fuel and air in order to heat the metal to a desired temperature. It is important that the forge is able to reach the correct temperature to soften the metal, but not so hot that it melts it. For iron, the appropriate temperature is 2500° Fahrenheit, or 1371° Celsius.

Shaping

Once the iron is properly heated, it can then be molded into shape. In order to do this, the metal must be first held securely in place using tongs, vises, and/or clamps, depending on the current shape of the material and the desired end result.

After the piece is secured, it is molded into shape using a hammer & anvil. The hammer and anvil are the most critical components of the forging process, as the quality of these tools determine the quality of the end result. This is why we only use the highest quality tools for this process.

There are several techniques used for shaping the iron, but there are three main ones that form the foundation:

• Drawing Out - The process of using force to draw the metal out of itself, increasing its length while also making it thinner.

• Upsetting - The process of applying force at the end of a piece in order to add volume or width

• Peening - The process involving the application of force to move metal in a specific direction. There are many different types of peens that can be used to create a variety of effects.

Quenching

After a metal is shaped, it must then be cooled. To accomplish this, the metal is placed in a quenching bucket. This bucket contains a unique mixture of mineral oils that harden the iron, as well as minimizing the the chances of warping or cracking.

Forged Iron Finishing Process

Once the iron has undergone the forging process, it is then finished with a powder coating. Powder coating is a high-quality finish found on thousands of products you come in contact with each day. Powder coating protects industrial machinery as well as many household items, including furniture.

Powder coating consists of a 4-step process:

• Blasting - Blasting removes any dirt, grime, or corrosion. All of our forged bases are sand-blasted.

• Prepping - Prepping consists of applying a metal prep chemical solution to remove surface impurities, clean off any lingering debris, and make the piece corrosion-resistant.

• Powdering - Once the piece is prepped, the coating is then applied. This is done through electrolysis, in which the metal object is positively charged in order for the powder to be attracted to it and bond well during the next stage. Please note that our powder coating is rated for indoor use only. Placing our pieces outside may damage the piece's coating, making it vulnerable to corrosion.

• Curing - This is the process of heating the powder-coated piece in order to strengthen the chemical bonds between the coating and the metal.

  Typical curing temperature ranges from 250°F to 400°F are required for the powder to heat up enough to bond.

Forged Iron Pros & Cons

Benefits

• Extremely Strong - Forged iron is less porous than cast iron since it is not melted prior to shaping. Because of this, the end product with superior strength.

• Simple & Sleek - Since forged iron pieces tend to have simpler shapes with sleek, straight edges, These pieces lend themselves well to modern fusion designs. The geometric shapes and simplistic nature of the piece perfectly fit modern design principles.

Drawbacks

• Limited Sizes - The forging process is best suited for smaller pieces. Larger pieces are simply too big to fit on an anvil, which is why sand casting is the preferred method for large pieces, such as consoles or cabinets.

• Limited Shapes - More intricate and complex bases are better suited for casting, as hand-forging has limited accuracy when it comes to fine details.

How We're Making Green Iron

We believe that great furniture doesn't need to hurt the environment. Iron is a strong, durable material that can be salvaged & recycled without sacrificing its qualities. Because of this, we elect to use only reclaimed iron. This iron comes in the form of remnants from our casting process or as scrap from various salvage yards. This ensures that we can create high quality products while also minimizing our overall carbon footprint.

Maintenance

Both cast and forged iron are extremely durable, corrosion-resistant, and strong. They require almost no maintenance outside of periodic cleaning. Here's some tips for keeping your iron clean:

• We recommend dusting your base once a week.
  

• If something spilled, wipe it off with a rag or sponge soaked in warm soapy water. Avoid using harsher chemicals like bleach, as this will wear down the finish.

• For additional protection, you can apply a light coating of non-abrasive car wax. This will serve to further ensure that finish is protected from sun damage.