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Production process Club series

You really have to see and feel the comfort of Max Jungblut seating sculptures to understand the quality and attention to details that emerged from a journey fraught with many difficulties and challenges. 

The “Club” series of seat sculptures are designed and manufactured entirely in the Netherlands. Our production process is the optimal end result of learning from experience and working with manufacturers and craftspeople across Europe over many years. 

A Search for Perfection

Searching for the perfect form, shape and size for the “Club” series was the beginning of an exhaustive process. Starting with “Searching Club I”, then using “Searching Club II” as a base (100%), scaled up models were produced in pinewood (104%), in walnut (107% & 110%) to arrive at a high comfort level for almost all body types/sizes when sitting in an active-passive position. The design was gradually perfected by producing and testing various prototypes before commencing production of the polyethylene “Club 111” model. 

The next stage was overcoming production challenges for the “112” model due to the unique design. Delivering a high quality hard wearing finish to complement the design aesthetics meant solving multiple problems, such as difficulties in upholstering concave shapes, hiding zippers and flattening seams to maintain the luxurious look and feel of the “Club 112”. 

This final production hurdle required finding an upholsterer with the perseverance and ingenuity to help Max create the ultimate sleek seating sculpture. Collaboration with a Dutch company found solutions for all the difficulties encountered in upholstering the unique design to the highest quality standards. 

Innovation

Continuous experimentation and analysis of multiple chairs produced across Europe with our upholstery partner resulted in novel solutions. Creative thinking identified new cutting and stitching techniques along with innovations in adhesion, bonding and pressing processes. 

This is why ’Club 112’ seats don’t use the upholstered panels often employed to camouflage flaws or overcut! Instead, 36 separate pieces of material are stitched together to create a single ‘skin’ incorporating three hidden zippers. The skin is then fitted over the base using an innovative heat treatment process to maintain shape and form without compromising quality and durability. 

Precision Cutting

Our upholsterers developed and documented precise patterns for cutting both foam underlay and upholstery materials into 36 parts using a CNC machine. 

Each foam part is individually glued to the polyethylene base to eliminate any underlay movement and the faceted edges align perfectly with corresponding sections of the upholstery. 

Expert stitching

Stitching the 36 separate sections of fabric or leather together is an enormous challenge from every perspective. Starting just 2mm out of position will have a significant visual impact all over the seat and may affect the durability of the upholstery itself. 

However, using a CNC machine to cut the material, before expert hand stitching by experienced craftsmen results in a masterpiece of the sewing department with barely noticeable flattened seams which enhance the seat’s design aesthetics. 

These craftsmen maintain the highest concentration levels for hours to stitch and thread 36 individual puzzle pieces and three hidden zippers together to create a perfectly shaped mistake-free skin for the 112. The zippers are located under the seat running from behind each front leg to the rear with the third running between the back legs.

Fixing the outer ‘skin’ to the seat

Upholstering the seat, which consists of double concave shapes, would be a challenge dreaded by any upholsterer. 

A complicated technique is used to keep the covering material secured in the concave and double concave shapes. A special glue, which is applied to the foam underlay and specific areas of the skin covering the sitting area, has to dry in a dust-free environment for 10 to 20 hours. After this drying period, the skin will be fitted in a very precise manner to avoid creating visible imperfections on the surface.

When the upholstery is ready, it is fitted over the seat frame. Closing the three zippers located under the seat pulls the complete skin tight and the heat press, with a constant temperature of 550 ° C (1022 ° F), presses the upholstery against the foam for a few seconds without scorching the upholstery to ensure a perfect fit over the entire surface of the Club 112.

By hiding the zippers and the careful application of the fabric, the chair bottom becomes the finest look and is a real piece of art.

We use woollen fabrics from Kvadrat, top quality leathers such as Aniline leather and sturdy maintenance-free artificial leather with strong UV protection ideal for public areas. Using the best quality materials, the proven technology of our customised heat press combined with the skills of our dedicated team ensures that every Club 112 is a timeless masterpiece. 

All materials and processes used have been extensively tested using a wide variety of methodologies.

LDPE outdoor models contain proven UV stabilizers and can withstand all weather conditions.

Weights:

Club 111 – Non-upholstered – 14.5 kg
Club 112 – Upholstered –  16.5 kg (approx. depending on materials used).