Adjustments in production costs linked to the redesign of wooden chairs for the bariatric population

Purpose Current furniture design principles fail to keep pace with the global rise in obesity. This study aims to address this issue by proposing a novel methodology for manufacturing cost estimation of common-use chairs that can accommodate even severely obese individuals. Design/methodology/approach The approach prioritizes universal design principles and user safety while ensuring furniture producers’ economic viability. This study utilizes real-world data to determine the establish appropriate load capacity for common-use chairs. Empirical height and weight data were collected from 7,938 young Slovakian men (aged 18–25) between 2001 and 2023. Additionally, data on Slovakia’s bariatric population, encompassing all genders, were obtained from medical facilities (2020–2024). Findings Considering the 95 th percentile weight among bariatric individuals, the authors factored in a 20% design safety margin. This resulted in a target load capacity of 230 kg for all chairs designed for common use – a significant increase from the standard 110 kg capacity. An essential contribution of this study is a method for estimating chair production cost based on its designed load capacity. This method’s calculations reveal that the redesigned chair is estimated to cost 11.6% more than a standard chair. However, considering its ability to cater to broader user needs, this price point remains competitive. Practical implications The research indicates that the standard load capacity of common-use chairs should be substantially increased to accommodate the growing obese population. The study offers a methodology for estimating the cost implications of designing chairs with a higher load capacity, enabling manufacturers to assess the economic feasibility of implementing such changes. Social implications Chairs with higher load capacities improve accessibility for individuals with obesity, promoting their participation in social and professional activities. By accommodating individuals of all sizes, these chairs reduce the risk of falls, injuries and other problems associated with poorly fitting furniture. Originality/value This study links universal design, safety and affordability. The authors used real data from Slovakia to find the right weight limit for these chairs. The study addresses the pressing issue of furniture design failing to keep pace with rising obesity rates. The method helps make chairs that are accessible to everyone. While these chairs cost a bit more, they are affordable considering their expanded user base. The study’s originality lies in its novel methodology and data-driven approach, while its value lies in its potential to address a significant societal issue.