Thrōn Made: Redefining Furniture Design Through Sustainable 3D Printing Innovation

As additive manufacturing continues its relentless march, pushing the boundaries of what’s possible in design and production, one sector where its transformative potential truly excels is furniture making. The convergence of captivating form, essential function, and crucial sustainability has given rise to a new era for designers. 3D printed furniture is unlocking unprecedented opportunities, enabling creators to delve into complex geometries, harness eco-friendly materials, and implement innovative production methods that traditional manufacturing often struggles to replicate or simply cannot achieve. This innovative approach offers a refreshing alternative to conventional techniques, paving the way for bespoke pieces that are not only visually striking but also environmentally conscious.

At the forefront of this exciting revolution stands Thrōn Made, a dynamic and ambitious brand brought to life by the visionary brothers, Sam and Jared Wesenick. Operating from Schofield, Wisconsin, United States, Thrōn Made proudly defines itself as “a true startup without large corporate funding delivering a set of 3D printed furniture to grow a community.” What initially began as an endeavor to powerfully demonstrate the advanced capabilities of industrial 3D printing technology has organically blossomed into a thriving creative venture. This enterprise masterfully intertwines the timeless artistry of craftsmanship with the precision and potential of cutting-edge innovation. From their steadfast commitment to utilizing biodegradable materials to their intricate, functionally driven designs, Thrōn Made’s holistic approach embodies the very essence of sustainable furniture for the future. To delve deeper into their inspiring journey, we recently had the privilege of speaking with Sam Wesenick, who shared insights into the compelling story behind Thrōn Made, their distinctive design process, and the profound ways in which 3D printing is fundamentally reshaping the landscape of modern furniture design.

3DN: Could you introduce yourself and tell us the story behind Thrōn Made?

My name is Sam Wesenick, and I’m collaborating with my brother, Jared Wesenick, to bring the vision of Thrōn Made to fruition. The genesis of Thrōn Made dates back to 2019, a period when Jared was actively exploring innovative avenues to showcase the impressive capabilities of the Compound Dynamics RM30 3D Printer. Driven by this ambition, he meticulously designed and then successfully printed the striking CD Lounge chair. This groundbreaking piece was then presented at several prominent trade shows, where it garnered overwhelmingly positive attention and feedback. The enthusiastic reception from attendees clearly indicated a strong interest in what we were creating. Fast forward to this year, finding ourselves with available printer time on one of our in-house industrial machines, we made the strategic decision to officially launch the Thrōn Made brand. Our goal was clear: to offer a distinct line of furniture that seamlessly merges superior functionality and robust sustainability with truly unique and captivating aesthetics. This pivotal moment transformed a technological demonstration into a dedicated brand committed to design excellence and environmental responsibility.

3DN: Can you walk us through your design process for 3D printed furniture?

Our meticulous design process for 3D printed furniture is inherently iterative and deeply creative, typically commencing with a surge of initial ideas. These sparks of inspiration can originate from various sources—perhaps a traditional furniture piece that caught our eye, or simply a spontaneous sketch on a notebook page. Once an idea begins to take shape, we transition it into the digital realm, meticulously modeling it using advanced CAD software. This crucial step not only solidifies the conceptual design but also generates the precise digital file required for the printing process. After the CAD model is finalized, we move to a vital testing phase: printing miniature models on our desktop printers. These smaller prototypes allow us to efficiently and cost-effectively assess the structural integrity of the design. We conduct rigorous weight-bearing tests, stacking various loads to ensure the design is robust and stable. This early-stage validation helps us identify and address any potential structural weaknesses before committing to a full-scale print. Only once we are confident in the structural soundness do we proceed to print the furniture piece at its full, intended scale. At this stage, any necessary adjustments are primarily focused on enhancing comfortability and ergonomics, based on practical assessments and user feedback. This continuous feedback loop ensures that each finalized piece not only meets our high standards for durability but also offers an exceptional user experience, ready for production.

3DN: What inspired you to choose 3D printing over traditional manufacturing methods, and what unique opportunities does it provide?

Our decision to champion 3D printing over conventional manufacturing methods stems from a profound sense of excitement and innovation. The furniture pieces produced through this technology are not merely products; they represent something genuinely new and invigorating in the market, a sentiment that truly fuels our passion. This cutting-edge technology empowers us with an unparalleled ability to experiment with highly complex and intricate shapes – designs that would be either prohibitively costly or outright impossible to realize using traditional woodworking techniques or conventional molding processes. Furthermore, 3D printing aligns perfectly with our core competencies, allowing us to leverage our skills where they are most effective and innovative. Beyond the aesthetic and design freedoms, 3D printing resonates deeply with our overarching goal of fostering sustainable manufacturing practices. It offers a pathway to minimize waste, optimize material usage, and create products with a reduced environmental footprint, cementing its role as a superior choice for the future of furniture production.

3DN: What 3D printing technologies and materials do you use, and how do they influence the final look, feel, and durability?

While we prefer to maintain a degree of proprietary discretion regarding the exact specifics of our technology, we can disclose that our primary material is a high-quality, plant-based biodegradable plastic. This innovative material starts its journey in the form of pellets, possessing a naturally clear and remarkably smooth finish. From this versatile base, we skillfully introduce one or two specialized colorants, allowing us to achieve virtually any desired aesthetic and vibrant hue for our furniture pieces. Our extensive research and development have involved considerable material and machine testing, which has yielded significant insights. Through this rigorous evaluation, we have perfected a method that allows us to print this unique material using large beads. This specific printing technique is crucial; it not only imparts a pleasingly smooth tactile feel to the finished product but also contributes immensely to its exceptional strength and robust durability. The result is furniture that is not only visually appealing and sustainable but also built to last, showcasing the intrinsic qualities of our carefully selected materials and refined printing process.

3DN: Sustainability is a big topic in design today. How do you incorporate sustainable practices and materials into your work?

Sustainability is not merely a trend for Thrōn Made; it is a fundamental pillar of our design philosophy and manufacturing process. Our commitment begins with our primary material choice: using plant-based plastic, which is a significantly more eco-friendly alternative to plastics derived from finite fossil fuels. This conscious selection dramatically reduces our reliance on non-renewable resources and lowers the overall carbon footprint of our products. In addition to our standard plant-based material, we proudly offer a specialized recycled option. This alternative incorporates 15% recycled material, which not only diverts plastic waste from overflowing landfills but also imparts a distinctive and appealing grayish, rainbow-like appearance to each piece, adding unique character without compromising quality or structural integrity. The ability to seamlessly integrate a combination of virgin and recycled materials is made possible by our advanced use of pellet extrusion technology, also known as fused granulate fabrication (FGF). Unlike the traditional filament used in smaller desktop 3D printers, FGF allows us to process raw plastic pellets directly, offering immense flexibility in material sourcing and composition. This method is also vastly more efficient; it enables us to extrude material at a rate ten times faster than typical desktop applications. This significantly higher throughput means our machines run for considerably shorter durations to produce the same volume of material, thereby drastically decreasing overall energy consumption. By embracing FGF and recycled materials, Thrōn Made not only crafts beautiful furniture but also actively contributes to a more circular economy and a more sustainable future for manufacturing.

3DN: Do you have any final thoughts for our readers?

Thrōn Made is more than just a small project; it is a venture driven by ambitious ideas and an unwavering passion for innovation. We are continuously learning and evolving, embracing the journey as we experiment with novel methods to create truly beautiful and functional furniture. Our latest explorations have drawn us towards the exciting synergy of combining advanced 3D printing techniques with more traditional craftsmanship. This hybrid approach allows us to produce pieces that feel distinctly fresh and contemporary, yet are still deeply grounded in timeless design principles and artisanal quality. We believe this blend creates a unique aesthetic that resonates with both modern sensibilities and an appreciation for heritage. If our vision and dedication to sustainable, innovative furniture speak to you, we would be incredibly grateful for your support on our Kickstarter page, which you can find HERE. Your contribution not only helps us grow but also empowers us to continue pushing the boundaries of what’s possible in furniture design. Thank you for your interest and support!

What do you think of Thrōn Made’s innovative vision for the future of furniture? We invite you to share your thoughts and feedback in a comment below, or connect with us on our LinkedIn or Facebook pages! For those keen to stay abreast of the latest developments in the additive manufacturing world, don’t forget to sign up for our free weekly Newsletter to receive the freshest 3D printing news directly in your inbox. Additionally, you can explore all our engaging videos and content on our dedicated YouTube channel.

*All Photo Credits: Thrōn Made