The Process

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Each design starts out with a drawing done in a CAD (Computer Aided Drafting) program. This allows the design to be played with and tweaked effortlessly until it looks "just right". Next, a full size pattern is printed. Pieces are cut from wood veneer using the pattern. These pieces are then taped together to form a face sheet called a "sketch face" (literally, a face sheet made from a sketch/drawing). This face is then glued onto a substrate, where it is sanded smooth and then incorporated into an exceptionally designed and executed piece of furniture. A very simple process.

Of course, there are plenty of opportunities for trouble. Because the veneer is only 6/10's of a mm thick (23.6 thousandth's of an inch), it is easy to sand through the face and into the substrate, ruining the piece; and because wood expands across the grain more than with the grain when it is wet (as in having glue applied to it)and because most fancy faces are made up with grains running in many different directions; and because each different species of wood, each different cut of wood, each different tree, each different section of a tree…, change size at different rates, it can sometimes result in bubbles forming in a pressing, ruining the piece; and because… Well I'm sure you get the idea. Suffice it to say that there is a failure rate, especially in new designs, making this process very much of an art, because it certainly ain't a science.

However, when it works, it is stunning!

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