DIY Modern Curved Plywood Lounger Chair

by Woodbrew
8 Materials
6 Hours
This week, we decided to put our design and engineering skills to the test by building a wooden live hinge lounge chair. The chair is made from 3/4" plywood and has walnut end caps. We used a technique called live hinge, where you take out material in a uniform pattern, which allows the plywood to compress and then bend.

BUILD FILES Check out the build files for this chair! Send us a link via Instagram DM to your modified version.

 Cut Your Plywood to Size. You will need a 30" x 24" piece of 3/4" plywood.
We used the Inventables X-Carve to cut our live hinge. You could use a jig saw if you don't have access to a cnc.Here are the files we used:
We decided to attach Walnut on either end of our plywood for added interest. The walnut is 3/4" x 5" x 24". We cut a groove in the end of the plywood and a tongue in the walnut.
Use clamps and glue to join them together.
Cut the legs out using the build files below. You will need to make two pairs of 3/4" plywood legs. Glue two pieces together to form a thicker leg.
Attach the legs to the chair with glue and screws. We plugged the holes to give a seamless look.
At both ends of the chair you need to cut a slot that is 1/8" x 1" all the way through the walnut. You will use this slot to attach the straps later.
We used a product called Waterlox to finish our chair. This is a super durable tung oil and resin infused finish. Check it out here:
We used 1" wide webbing straps for holding the chair up. We used rivets to attach the straps.
Add adjustable connectors to allow you to adjust the back position.
Suggested materials:
  • Waterlox Finish   (
  • X-Carve Machine   (
  • Easel   (
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Frequently asked questions
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