limbo/bluff chair
The Limbo Chair and Bluff Chair are versatile lounge seats designed for both domestic and outdoor environments, developed during my internship at Atlason Studio in New York for Heller Furniture. The project centers on the marriage of high-end lounge aesthetics with the technical precision of rotational molding.
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problem
The primary objective was to achieve a seemingly effortless appearance that masks a rigorous engineering foundation. We needed to balance the oversized, swooping geometry required for comfort with the material constraints and consistency required for large-scale rotational molding.
solution
Initiated by a challenge from Heller CEO John Edelman to Hlynur Atlason, the brief sought a modern lounge chair that exudes both supreme comfort and statement style. The result is a sculptural piece that functions seamlessly across indoor and outdoor settings while upholding strict ecological standards.
01 Design Story
The brief was deceptively simple: design a universal lounge chair. Beneath that simplicity lay a layered challenge—the form needed to be visually striking, ergonomically inclusive, and optimized for large-scale rotational molding. Working under a compressed timeline, I led the development of a comprehensive research and concept proposal, establishing early alignment with Heller’s leadership. By maintaining proactive communication and daily checkpoints, I delivered a focused strategic deck—incorporating material benchmarks and form explorations—that served as the foundation for the entire design phase.
02 Research & Ideation
My initial research identified critical market drivers that informed the collection’s DNA
Key Trends: Emphasis on bold, sculptural silhouettes, playful design language, and rounded, low-maintenance surfaces.
Circularity: The use of recycled plastic not as a secondary feature, but as a primary aesthetic and functional driver.
Opportunity: To innovate with Low-Density Polyethylene (LDPE), transforming a utilitarian material into a signature, high-comfort seating solution.
03 Sustainability as a Systemic Priority
Sustainability was the core design driver rather than a post-script. I focused material research on finding a solution that supported a truly circular lifecycle. After benchmarking performance and recyclability, I proposed post-consumer recycled LDPE—a UV-stable, flexible material ideal for indoor-outdoor use. By analyzing industry benchmarks, we determined that the black variant could achieve nearly 100% recycled content, marking a bold leap in Heller’s sustainability journey and anchoring the chair’s identity as a modern, circular product.
04 Form Development
To translate the conceptual DNA into a physical statement, I utilized a rapid ideation process, producing dozens of form explorations with each sketch strictly limited to a three-minute window. This high-volume approach allowed for an expansive exploration of "swooping" silhouettes and the iconic three-legged architecture.
Each sketch took 1-3 minutes.
The evolution of form was intrinsically linked to ergonomics. By layering human-scale underlays directly beneath the sketches, I refined the chair’s profile in real-time, ensuring that the playful, rounded edges provided a rigorous and comfortable cradling effect.
05 CAD & Collaboration
Bridging creative vision and industrial reality, I worked closely with Heller’s engineers and factory technicians to deliver precise CAD and specification packages. My role focused on refining DFM (Design for Manufacturing) files for rotational molding and supporting full-scale 3D printing. This iterative testing was crucial to validating the ergonomic assumptions made during the sketching phase, ensuring the final sculptural form was both scalable and signature.
Tactile Durability: A soft matte texture was selected to enhance durability and conceal fingerprints in high-traffic settings.
Functional Detail: Integrated drainage holes prevent water pooling, reinforcing the collection’s all-weather performance while maintaining its seamless, sculptural logic.
Renders of the CAD Model of Limbo and Bluff Chair made in SolidWorks.
Full-scale 3D printed prototype.
The manufacturing was processed with Heller's rotational molding factory (after my internship ends).
06 CMF Strategy
Limbo and Bluff were envisioned as a scalable system rather than standalone pieces. We curated a muted, nature-inspired palette designed to harmonize with diverse environments—from private patios to public gallery spaces.
07 Into the Market
Launched in 2023, the collection defines a new standard in "Worry Free Plastics." Manufactured in the USA and 100% recyclable, these pieces achieve a "supreme comfort" experience that has received extensive industry acclaim:
Winner: 2023 Cooper Hewitt National Design Award
Winner: 2023 Interior Design Best of Year — Outdoor
Winner: 2023 HiP Award: Outdoor Seating
Winner: 2023 Architectural Record: Best Outdoor Product
Award of Merit: 2024 AZURE Magazine Furniture Award
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