How is an Eames Lounge Chair Replica Made?

The Eames Lounge Chairs and Ottoman officially named Eames Lounge (670) and Ottoman (671), were released in 1956 by Charles and Ray Eames. Their design resulted in one of the most iconic and recognized representations of American mid-century modernism. 

Charles and Ray Eames worked closely together while creating the Eames Lounge Chair. They brainstormed and experimented with several common materials, but decided for their all-time favorite: molded plywood. Both designers toiled relentlessly on their designs until they got every last detail right. 

Manhattan Home Design offers a replica of this masterpiece, following all original specifications with the same accuracy and attention to detail. Their process and replicas have been voted the closest to the original, and have shared the behind the scenes of their manufacturing process.

How the Eames Lounge Chair Replicas are Made

Manhattan Home Design’s manufacturing process is almost the same used for the original Eames Lounge Chair. All of their Eames Lounge Chair replicas are mostly made by hand.

The Leather

It all starts with the highest quality leather. Leather pieces are laid out and examined for any imperfections. They are searched for any markings, flaws, scars, bug bites, or defects. 

These flaws are picked up by a computer scanner which then calculates the best way to cut the leather and avoid imperfections. This same computer also cuts the leather, creating all the pattern pieces for the Eames Lounge Chair cushions. 

The Sewing Process

Manhattan Home Design has no automation in this part of the process. They are true believers of hands-on American craftsmanship. Every one of their Eames Lounge Chairs is hand sewn. They start by sewing the arms, the seats, and back pieces. Then the cushions go to the upholsterers to be stuffed with high-density urethane foam.

Buttons are then hand sewn in place using a sturdy twine. Each button is placed in a way that when you put your legs up on ottoman it’s already compliant and adapting to your body. These buttons provide give the Eames Lounge Chair replica their shape, strength and its iconic appeal.

The Woodwork

Manhattan Home Design offers plywood or walnut veneer sheets, depending on your choice. These are fed into a conveyor where a coat of glue is placed on both sides. The plywood sheets are then combined by alternating dry sheets with glued ones. The wood grains are crossed for added strength in this part of the process. The wood grain that you choose gives the Eames Lounge Chair replica a lot of its character. 

When the manufacturing process originally began in 1956, rosewood was the high-end look to get. Since using rosewood from Brazil was discontinued in the early 1990s, Manhattan Home Design uses seven plywood layers covered by environmentally friendly walnut or palisander veneers.

Afterward, the layered veneers go into a press which applies a precise amount of heat and pressure to bend the wood. This process hasn’t changed much since 1956. Then a computerized routing arm cuts out the shapes of the seat, the back, headrest, and the Ottoman base.  

The Shock Mounts

After all the woodwork is done, the circular impressions where the shock mounts will go are sanded. Shock mounts were another clever invention of Charles and Ray Eames. The shock mounts isolate various pieces of the Eames Lounge Chair and allow it to move with your body. This is what helps the Eames Lounge Chair move comfortably with you.

The plywood pieces go through a final sanding and then on to the assembly area. After the assembly team double-checks that everything matches, all the connecting hardware is attached and the Eames Lounge Chair seat undergoes a shock mount test.

The Final Tests

The shock mount for an Eames Lounge Chair replica is probably the most critical aspect of the chair. Manhattan Home Design states this is the process that they spend the most amount of time on. 

After the shock mount test, the wood sheets and leather upholstery are merged. The signature 5 leg base is screwed on and each cushion is carefully nudged into its plywood shell. Then the final hardware is attached.

There’s one final step before each Eames Lounge Chair replica is ready to sell. Every one of Manhattan Home Design’s Eames Lounge Chair replicas receives a final shock mount and rocking test to confirm everything is okay and the shock mounts are doing their job.

It’s no wonder our Eames Lounge Chair replica continues to be one of their best selling pieces. Whether it’s the materials used or the upholstered leather, the Eames Lounge Chair remains an icon of comfort, elegance, and modernism. 
You can order your Manhattan Home Design Eames Lounge Chair replica now, and join this Lounge Chair most exclusive and coveted owners club!

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