The craft of Solo Bar Stool by Neri & Hu begins with the skilled selection of planks chosen for strength and consistency. A craftsperson uses a template to draw the leg shapes onto the timber, nesting them into one another to make maximum use of the plank, while carefully avoiding any knots. The leg shape includes a branch-like limb to allow for a smooth transition between components. The leg forms are rough cut on a bandsaw before being run through the CNC machine.
The four legs are joined by a cross brace. The cross brace assembly is made of two parts, each of which is cut on the CNC before being joined with a long grain to long grain lap joint. This pre-assembly is then run through the CNC again.
The cross brace and the brass footrest are both attached to the four legs using mortise and tenon joints. A jig is used to allow a craftsperson to accurately assemble all of the parts of this complex leg structure. The joints are hand adjusted before the entire frame is sanded and finished, also by hand.
Once the leg structure is finished, it is attached to the upholstered seat shell with discreet bolts located under the seat pad. The seat shell is handmade from layers of glass fibre and resin pressed into a mould. This creates a form that is slender and lightweight with great strength. A thin skin of foam cut from a carefully designed pattern, is hand-applied to the fibreglass shell. The final layer of luxurious textile is then hand stretched, glued and stitched to the shell. A memory foam cushion is used on the seat.