The Wrap Lounge Chair by Muuto is instantly recognisable for its generous, soft proportions and inviting appearance. Designed by Normal Studio, the chair combines a blanket-like textile that wraps around the shell with a lightly powder-coated steel frame, a carefully balanced interplay of tactility and technical clarity.
Behind this seemingly effortless design language lies an essential yet invisible element: a thermo-formed felt inlay, developed by G-Desmet. This internal structure forms the foundation for comfort, stability and a more sustainable approach to production.
From design vision to technically feasible lightness
For Muuto, it was crucial that the Wrap Lounge Chair retained its characteristic ‘wrapped’ expression without relying on a traditional internal metal structure. Such an approach would not only increase weight, but also limit flexibility in material use and finishing.
G-Desmet was therefore invited to collaborate on the development of a sustainable alternative: an internal base structure that follows the complex 3D contours of the design, provides optimal support for upholstery, and remains lightweight and material-efficient.
The solution was found in thermo-formed felt, a material that is highly shapeable, requires relatively little raw material, and allows structural strength to be combined with minimal mass. The felt inlay forms the complete internal shell on which Muuto can upholster and finish the chair, while remaining entirely out of sight.
Why thermoformed felt? Sustainable, lightweight and thoughtfully engineered
The choice of felt was the result of a deliberate consideration of design, production and sustainability:
- Significant weight reduction, resulting in lower material use and more efficient transport
- A more sustainable alternative to metal inner structures by avoiding heavy, energy-intensive materials
- Excellent formability, ideal for complex and soft 3D shapes
- Long-term durability thanks to dimensional stability and structural strength
- Highly suitable for upholstery, allowing easy fixing by stapling or fastening
- Consistent fit, essential for stability in combination with Muuto’s metal base
Together, these qualities make thermo-formed felt a forward-looking solution for upholstered seating furniture.
An iterative process of form studies and prototypes
In close co-creation with Muuto, G-Desmet followed an extensive development trajectory, including:
- Thermo-forming trials
- Fit and contour studies
- Multiple prototyping phases
- Testing for tension, shape retention and upholsterability
Each iteration refined the felt structure further, bringing the design closer to the right balance between aesthetics, comfort and technical sustainability. The result is an internal component that remains invisible, yet plays a defining role in the quality and experience of the chair.
G-Desmet’s contributions
- Development of a thermo-formed felt inlay as the internal base structure
- A lightweight and sustainable alternative to traditional metal inner frames
- Precision in contours, tolerances and complex 3D geometry
- Extensive prototyping and testing in close collaboration with Muuto
- A production-ready solution ensuring consistency and quality in serial manufacturing
Shaping forward-thinking furniture design together
The Wrap Lounge Chair demonstrates how design and technical development reinforce one another when sustainability is considered from the very beginning. For G-Desmet, this project perfectly reflects our approach: translating design visions into refined, manufacturable and responsible solutions for international design brands.
Curious how we can support your furniture concept with thermo-formed components, material expertise and production know-how?
Feel free to get in touch, we’re happy to think along from the very first sketch.
