Layer and KFI Studios Transform Plastic Waste into Stylish, Sustainable Furniture

FDT Bureau

London-based design studio Layer has partnered with US furniture brand KFI Studios to create the Vale Collection, a line of furniture wrapped in eco-friendly PET felt, revolutionizing sustainability and combating plastic waste. This collection is a response to the escalating plastic waste crisis, transforming recycled plastic into stylish and functional furniture. Know more about it on FURNITURE DESIGN AND TECHNOLOGY (FDT).

The Vale Collection features chairs and stools made from felt crafted out of recycled PET bottles—87 bottles for each chair. This plastic is spun into a non-woven felt and then heat-pressed into shape, resulting in a soft, impact-resistant material. The collection includes a side chair, armchair, lounge chair with ottoman, low back counter stool, low back barstool and high back barstool. Each piece combines comfort, durability and eco-friendliness, offering a sustainable alternative to traditional furniture.

The production process begins with collecting used plastic bottles from recycling centers and consumer collection programs. These bottles are sorted, cleaned, shredded into small flakes and then melted and extruded into thin fibers. These fibers are processed into a non-woven fabric through needling or hydroentangling, resulting in robust and flexible PET felt. The felt is then cut and shaped to meet the design requirements of the Vale Collection. The PET felt offers several advantages: it is durable, resistant to wear and tear, provides excellent sound absorption and offers good thermal insulation. Additionally, it reduces the demand for virgin plastics and helps mitigate plastic waste. The environmental impact of producing PET felt from recycled plastic bottles is significant, diverting waste from landfills and consuming less energy compared to producing new plastic, resulting in lower greenhouse gas emissions.

The design of the Vale Collection is inspired by rolling hills, with minimalist aesthetics achieved through simple bolts for easy removal and recycling. The name Vale, derived from the Middle English word for valley, reflects the unique design feature of the rolled edge that gives the chairs a warm and inviting feel. The stackable design makes it ideal for various settings, including offices, institutions and homes. The recycled PET felt is available in six colours —Charcoal, Grey, Stone, Midnight, Sage and Garnet—while the steel frame comes in seven shades—White, Black, Silver, Quartz Grey, Sapphire Blue, Pale Green and Oxide Red. This array of colours allows for custom looks or coordinated monochromatic aesthetics. An upholstered seat pad, available in various textiles or COM, can be added for additional comfort.

By utilizing PET felt, the Vale Collection significantly reduces plastic waste, transforming discarded plastic bottles into valuable furniture components. This process exemplifies a circular economy approach, repurposing waste into new, useful products. The collection promotes awareness of the potential of recycled materials, encouraging consumers and manufacturers to consider sustainable alternatives.

Image credit: Layer and KFI Studios