Have you ever wondered why ergonomic furniture costs so much? Here’s a secret: creating curves that actually fit the human body is ridiculously complicated. Our bodies are all soft lines and organic shapes, but transforming hard materials like wood into those comfortable contours usually requires serious craftsmanship, expensive machinery, or both. Designer Minhwan Kim just cracked this puzzle in the most elegant way possible, and the design world is taking notice. Layer, his recent furniture project, just won Red Dot’s prestigious “Best of the Best” award for 2025.
The genius of Layer lies in how it rethinks an old problem. Traditional curved furniture typically means either steam-bending wood (labor-intensive and temperamental) or carving from solid blocks (hello, massive waste). Some designers have experimented with parametric structures, which use flat sheets cut into specific patterns that can be assembled into three-dimensional curves. It sounds perfect in theory, but there’s a catch. These designs often waste huge amounts of material because the cutting patterns don’t efficiently use the available sheet space. You end up with gorgeous furniture and a dumpster full of expensive scraps.
Designer: Minhwan Kim
Kim’s approach flips this wasteful equation. Layer uses an optimized parametric system that minimizes material waste while creating furniture that looks like it was sculpted rather than assembled. The process starts by digitally breaking down a 3D curved surface into individual layers. Think of it like those topographic maps that show elevation through contour lines, except here each line becomes a physical piece of wood. These intersection curves are then aligned and processed into solid wood components that stack together to create the final form.
The beauty of this system is visible in the finished pieces. That curved seat you see isn’t molded or carved. It’s actually dozens of thin wooden layers precisely cut and stacked, creating a fluid, organic surface that perfectly supports the human form. The wood grain flows across the surface like waves, emphasizing the layered construction rather than hiding it. It’s functional sculpture that actually works as furniture.
What really makes this project special is how it bridges digital design and traditional craftsmanship. The parametric modeling happens on a computer, allowing Kim to optimize every cut for minimal waste. But the actual fabrication involves real woodworking, real routers and sanders, and actual human hands assembling each layer. You can see this in the workshop photos where curved wooden ribs are being clamped together, sawdust coating the workbench, showing that even cutting-edge design still requires getting your hands dirty.
The manufacturing process is surprisingly straightforward once you understand the system. Standard flat plywood sheets get CNC-cut into the calculated patterns. Because the system is optimized, the pieces nest together on the sheet like a jigsaw puzzle, using nearly every inch of material. These flat pieces are then processed into their final curved profiles through careful routing. Finally, they’re assembled layer by layer, each piece fitting into precisely calculated positions until the complete three-dimensional form emerges.
This isn’t just clever for its own sake. In an era when we’re increasingly aware of material consumption and waste, Layer demonstrates how thoughtful design can be both beautiful and responsible. The furniture industry generates enormous amounts of waste, particularly in custom and high-end pieces. By optimizing material usage from the digital design phase, Kim shows that sustainability and aesthetics don’t have to be competing values.
The finished stool in the exhibition space looks deceptively simple. Its dark wood surface curves gently to cradle the body, the layered edge visible like the pages of a closed book. Nothing about it screams “innovative fabrication technique” or “award-winning design.” It just looks like a really nice piece of furniture you’d actually want in your home. And maybe that’s the highest compliment you can give any design: it solves complex problems so elegantly that the solution becomes invisible.
For anyone interested in where design and technology intersect, Layer represents an exciting direction. It shows how computational design tools can enhance rather than replace traditional craft, and how constraints like material efficiency can inspire creative solutions rather than limiting them. Sometimes the most innovative designs aren’t about flashy new materials or radical forms, but about finding smarter ways to work with what we’ve always had.
The post This Furniture Trick Makes Flat Wood Look Curved With Zero Waste first appeared on Yanko Design.