The journey from a spark of an idea to a finished piece of outdoor furniture ready for production is a meticulous one, centered on rigorous prototyping. Our process begins not with tools, but with conversation and sketches. We explore the core need: Is it for deep relaxation, elegant dining, or durable poolside use? Initial hand-drawn sketches translate these concepts into tangible forms, considering proportions and basic aesthetics.

Next, we move into digital modeling. Using 3D CAD software, we create a virtual prototype. This stage is crucial for refining dimensions, ergonomics, and structural integrity. We can simulate stresses and material behavior, making adjustments that would be costly and time-consuming later. Photorealistic renderings allow us to visualize the piece in various environments and colorways.

The most critical phase is building a full-scale physical mockup. We often use cost-effective materials like plywood, foam, or even recycled components to create a "looks-like" model. This prototype is for form and feel—we assess its visual presence, comfort, and spatial relationship. We sit on it, move it around, and live with it outdoors.

Following this, a "works-like" functional prototype is built using materials closer to the final spec, such as target metals or treated woods. This model undergoes rigorous testing for stability, weight capacity, and assembly mechanics. We expose it to elements in our testing area, gathering data on performance and durability.

Throughout, we test material samples for fade resistance, texture, and maintenance. Feedback is gathered from our design team, manufacturing engineers, and trusted potential users. Each iteration refines the design, solving problems before they reach the factory floor. The final prototype, along with detailed technical packages, is then handed off to production, ensuring the manufactured furniture is beautiful, functional, and built to last.