Abstract: A method for manufacturing a chair assembly (20) with a customized backrest (46) includes fabricating a standardized frame (22), preparing a contoured plywood blank (48) for the backrest (46), selecting a customized design for the backrest (46) and then converting the design for the backrest (46) into a readable format, loading the readable format for the backrest (46) design into a customized cutting apparatus, loading the blank (48) into the cutting apparatus, cutting the blank (48) in conformity with the selected backrest (46) design, removing the completed blank (48) from the cutting apparatus, mounting the backrest (46) onto the frame (22), and lastly, mounting a seat (36) onto the frame (22).

Abstract: A chair includes a base, a backrest and a back brace supporting the backrest from the base. The base may include a seat assembly made up of a pan and a flexible support membrane over an upward opening cavity defined by the pan. The back brace may provide a flexible support for the generally planar member formed as a serpentine shape defined by a first curved portion opening toward said base and a second curved portion opening away from said base. The backrest may have an outer frame made from an extruded member having a generally tubular member and a fin coextruded with said generally tubular member to provide a fastening substrate for panels. The base may further include a leg assembly made up of a plurality of leg members and a joiner member joining horizontal portions of the leg members.