Designer Minhwan Kim Revolutionizes Furniture with Zero Waste Technique

Designer Minhwan Kim has garnered attention for his innovative approach to furniture design, winning the prestigious Red Dot award for “Best of the Best” in 2025. His project, named Layer, offers a sustainable solution to the complexities of creating ergonomic furniture that seamlessly fits the human body.

Creating curves that are both functional and aesthetically pleasing has long posed a challenge in furniture design. Traditional methods often rely on labor-intensive techniques such as steam-bending wood or carving from solid blocks, which can result in significant material waste. Kim’s breakthrough lies in his optimized parametric design system, which minimizes waste while achieving the desired organic contours.

Innovative Design Process

The core of Kim’s approach involves digitally breaking down a three-dimensional curved surface into multiple layers. This method resembles topographic maps, where each contour line translates into a physical piece of wood. The resulting components are then stacked together, creating a fluid surface that supports the human form. The final products showcase the beauty of layered construction, with wood grain flowing across the surface, emphasizing the craftsmanship involved.

What sets Layer apart is its ability to merge digital technology with traditional woodworking techniques. The design phase employs advanced parametric modeling to ensure optimal cuts that reduce waste, while the fabrication process relies on skilled artisans who use standard woodworking tools. Photos from Kim’s workshop illustrate this blend of technology and craftsmanship, with curved wooden components being assembled by hand amidst a backdrop of sawdust.

Sustainability Meets Functionality

The manufacturing process for Layer is both efficient and streamlined. Standard flat plywood sheets are CNC-cut into shapes that nest together like a jigsaw puzzle, maximizing the use of material. Each piece is then carefully routed to achieve its final curved profile before being assembled layer by layer. This meticulous process not only reduces waste but also demonstrates that thoughtful design can be both beautiful and responsible.

In a time when material consumption and waste are pressing concerns, Kim’s work serves as a model for the furniture industry, which traditionally generates substantial waste, especially in custom and high-end pieces. By integrating sustainability into the digital design phase, Layer exemplifies how aesthetics and environmental responsibility can coexist.

The final stool from this project, featured in an exhibition, presents a deceptively simple design. Its dark wood surface curves gently to cradle the body, with the layered edge visible like the pages of a closed book. This elegant solution does not overtly advertise its innovative fabrication technique, but rather stands as a testament to effective design that addresses complex challenges without drawing attention to itself.

For those invested in the intersection of design and technology, Layer represents a promising direction. It illustrates how computational design tools can enhance traditional craftsmanship while adhering to material efficiency. In many cases, the most innovative solutions arise not from radical new materials or forms but from smarter ways to utilize existing resources.

As the furniture industry continues to evolve, Kim’s work exemplifies the potential for design to adapt to contemporary challenges, paving the way for a more sustainable future.