DIY No Glue Cardboard Chair

In the following steps I will you show the, materials and assembly process so you can build this chair that looks like a bubble using only cardboard.

1. 4mm corrugated cardboard
2. Cutting board
3. Cutter
4. Plotter
5. Laser cutter
6. AutoCAD (if planning on using a laser cutter)

To assemble this chair, you can either use the templates or laser cut the pieces. In both formats you can see the name of each piece which will help guide you through the process.

In any way you choose to do it, an important recommendation is to make sure the pieces are placed with the correct orientation along the cardboard.

Unlike regular cardboard, the one we are using is made of two different structures placed together like a sandwich. On the sides you have two linerboards keeping everything in place. Between them is a wavy paper sheet called flute, which can resist compression by helping distribute weight evenly. The flute creates vertical inner columns so when pressure is applied in the same direction as these “columns”, the vertical support prevents it from collapsing.

For better results with this model, it’s important that weight bearing structures are cut with the “column” support going vertically trough the piece.

If you are planning on cutting them by hand, you can print the templates on ISO A0 paper. Once you have them printed out, you will know how many of each piece to cut.

For the dotted lines, you will need to use less pressure for the cut, ensuring that it doesn’t go through the last piece of paper on the outer side of the cardboard. For two dotted lines together, you have to “fold” the cardboard inward. If it is too difficult you can remove the excess paper from the flute that is left between the cuts. It should look like this.

This will help create folds in the cardboard without damaging it.

You can also laser cut the pieces using this AutoCAD file. When cutting them, you can arrange the blocks in different directions, so they are correctly placed along the flute structure. This model uses two different layers, one for cutting, and the other for engraving.

For engraved pieces you should follow the same instructions as with the dotted lines of the ones cut by hand.

Once you have all the pieces you can begin to assemble the chair.

To assemble the chair structure you will need

1. Edge piece – 4x
2. Middle piece – 6x
3. Center A – 2x
4. Center B – 2x
5. Center C – 2x

First grab two EDGE pieces and both CENTER A pieces to join together with interlocking slots. You will notice the EDGE piece has three grooves on the lower side. You are going to insert the one that is closest to the curve into the groove on the edge of the CENTER A piece.

Then repeat the process with the other two center pieces. CENTER B goes with the middle groove of the EDGE piece, and CENTER C goes into the one closest to the back of the chair.

After that, inset the remaining EDGE pieces onto the grooves on the other side of the CENTER pieces.

Do the same with the MIDDLE pieces, inserting two of them into each space.

Use the CROSS RAIL piece and make sure you can bend it inward using the semi-cut spaces it has.

Fold it together so it creates a rectangular shape.

Insert this shape into the holes of the EDGE and MIDDLE pieces. This will keep the back of the pieces from sliding or deforming.

Once the CROSS RAIL goes trough all the pieces you are ready for the next step.

To assemble the seat and back of the chair you will need all the SEAT, BACK and BASE pieces.

A recommendation to cut the SEAT/BACK and BASE pieces is to alternate the direction of the flute between them. As the SEAT/BACK pieces will go on top of the BASE pieces, having the flute going in different directions for both will help distribute weight better.

One SEAT + one BASE piece placed on top of the other is a pair.

With one A pair, insert the flaps of the SEAT A piece into the grooves on the EDGE pieces starting from below.

Then place another pair so that each groove will have two flaps from different pairs.

Repeat the process for the rest for the other SEAT A pieces. When you reach the final one, there will be one SEAT A piece and two SEAT A BASE. Place all three of them together like you did for the others. Having three supporting pieces closer to the area where more force will be applied is going to prevent the cardboard from bending.

Using the same process place SEAT B pair. The side with shorter flaps goes next to SEAT A.

Place SEAT C pair

Pace SEAT D pair, with the longer flaps next to SEAT C

Next grab the BACK A pairs and place three of them into the next grooves on the back of the chair.

Use the BACK B piece and place it into the next set of grooves. Make sure you can bend it inwards so it will curve along the shape of the back.

Place the BACK C piece the same way.

Place the remaining BACK A pair into the last set of grooves.

Grab the BACK STRETCHER piece and make sure you can bend it inward along the cuts.

To make it easier to place, flip the chair over.

You will notice that the BACK STRETCHER has one part that is longer (7cm) than the other (6cm) after the dotted or engraved lines on each side. Place the piece on the grooves on the base of the chair with the longer side here. Then curve the BACK STRETCHER piece so that it can go into the grooves on the back.

Flip the chair back up.

Congratulations! Your chair is almost finished.

However, it is most likely that when you try to move it, the SEAT or BACK pieces will start to become loose, making them more likely to get damaged. That is why there’s a set of EXTRA SUPPORT pieces that you can use to make the chair more stable.

Grab one EXTRA SUPPORT piece and place it between the flaps of the SEAT/BASE pieces. Puch it in until the piece is hidden from view. You can use a ruler, pen, or kitchen knife to do it.

Repeat this process in all the pieces that feel loose to the touch.

Now you can replicate it and have your own bubble chair to use in any space. You can make them in different sizes by scaling the pieces. If the SEAT/BACK pieces bend with time, you can cut more and replace them so you can always keep your chair looking like new.