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  1. How they make it

    Package

    After more than 100 steps, the completed parts are ready for packaging. Workers assemble the upper container, filter funnel, gasket, and boiler in much the same way that the eventual user will put...

    01.01.09

  2. How they make it

    Shear and Coin

    The metal-punching facility is down the road from the Magis headquarters in Motta di Livenza, in northeastern Italy. Steel sheets, 191⁄2 inches high, 45 inches wide, and less than 1⁄16-inch thick,...

    01.01.09

  3. Perimeters
    How they make it

    Perimeters

    The next tool makes a perpendicular fold around the sheet’s perimeter, which allows the hard edges to be folded away from the smooth backrest. Parts of this fold will become armrests. &ldquo...

    01.01.09

  4. Cuts, Curves, Cuts
    How they make it

    Cuts, Curves, Cuts

    The tool that folds the curve of the back of the chair is the most dramatic, but it is no more essential than the others, which trim the edges, cut the holes, and add a final soft angle to the...

    01.01.09

  5. How they make it

    Fitting Wood

    Four straight legs and a round seat are CNC-milled out of solid beech, bolt holes and all, ready for fixing to the punched and painted steel. As the chair began production in early 2008, the...

    01.01.09

  6. Molten Dust
    How they make it

    Molten Dust

    Piombino Dese, a drab industrial town between Venice and Verona, has many small glass companies, including Vetrerie New Glass, founded by Franco Pellizzon in 1991 and one of several Glo-Ball...

    01.01.09

  7. Blow Mold
    How they make it

    Blow Mold

    When the blob has reached a diameter of about six inches, it has already been handled by two or three blowers, who multitask like chefs.

    01.01.09

  8. How they make it

    Cool and Cut

    Vetrerie New Glass can make 18 Glo-Balls per hour—Pellizzon keeps the operation tight in order to guarantee exceptional quality. The balls sit in a slow-cooling kiln for two hours; otherwise, they...

    01.01.09

  9. Put Together
    How they make it

    Put Together

    West of Piombino Dese, in Bovezzo, the well-tended Glo-Balls meet the other parts of the lamp: laminated tubular steel stands, bases, and electronic components sourced in Milan. At first glance the...

    01.01.09

  10. How they make it

    Sketching

    Little Field of Flowers was first conceived in 2005, when, in the cyclical course of design trends, flowery was at the height of fashionability. Nani Marquina says, “We thought it would be nice to...

    01.01.09

  11. How they make it

    Prototyping

    “We ordered the first prototypes in an embossed pattern,” explains Marquina, who works with several Indian manufacturing facilities. The Nanimarquina team instructed the manufacturers to use a...

    01.01.09

  12. How they make it

    Die Cutting

    As Boontje’s signature style is often associated with cutouts, Marquina’s solution was a good fit. Sheets of felt from Rajasthan go into a die cutter, which is essentially a combination of a waffle...

    01.01.09

  13. Weaving
    How they make it

    Weaving

    Depending on the size of the rug—they come in three sizes—one or two technicians at SPN operate the loom, which involves painstaking manual labor. “Every two or three lines,” Marquina explains, “we...

    01.01.09

  14. How they make it

    Cut

    Organic merino wool arrives from Vermont, woven and mounted on rolls over a yard and a half wide. When asked what makes the wool organic, Notkin explains that the sheep grazed on pesticide-free...

    01.01.09

  15. How they make it

    Prep

    Zippers, buttons, and other add-ons are rendered unnecessary by Looolo’s pillowcase closure system, which uses a tried-and-true technique: overlapping flaps on the back. “Zippers and...

    01.01.09

  16. How they make it

    Pattern

    Notkin, who started her career making costume jewelry, has a knack for romantically contrasting hues and textures. In fact, her favorite part of the creative process comes before anything is made...

    01.01.09

  17. How they make it

    Stuff

    The fronts and backs are sewn to each other inside out and then turned right side out—“we just make sure the corners are nice,” says Notkin. Each pillowcase is hand-stuffed with a...

    01.01.09

  18. How they make it

    Concept

    On every scale, from cottage industry to mass market, production starts with research. Johnstone begins by scouring the globe for team members who have the right skills and design sense to match a...

    01.01.09

  19. How they make it

    From 2-D to 3-D

    “Very aggressive” is how Johnstone describes the design schedule. They move quickly from a few rough sketches to a virtual 3-D model. AMOI and HWL take advantage of the time difference, working on...

    01.01.09

  20. How they make it

    Prototyping

    After the sketch-overlay and technical-design phases, AMOI provides a 3-D model. In the nine months that follow, the shape is subject to intensive prototyping before delivery to the factory line. ...

    01.01.09

  21. How they make it

    Finishing

    When finishes are chosen and every-one has signed off, the factory line begins to churn. “We do a short production run of about 500 phones,” says Johnstone, “and use them heavily to gather feedback...

    01.01.09

  22. How they make it

    Dumpster Diving

    The first step in the Scrapile process is to acquire raw materials. Salgado and Bettencourt are beggars, not choosers: Any wood—from cherry to walnut—will do. With help from a local...

    01.01.09

  23. How they make it

    Building a Block

    With raw material in hand, they painstakingly assemble their scraps into a solid, ten-foot-long block that is eight inches square. To achieve the striated pattern of cascading bands that is...

    01.01.09

  24. A Design Emerges
    How they make it

    A Design Emerges

    All of Scrapile’s sharp modern forms come from the solid block of wood. The pieces have evolved from basic, boxy shapes to more complex lines as Salgado, who does most of the design, has...

    01.01.09

  25. How they make it

    Putting It Together

    With a design in place, the block is trimmed down to size, planed, sanded, and edge-cleaned. Planks are cut with precision, to ensure the waterfall pattern aligns exactly, and pieces are glued and...

    01.01.09

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