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Say No To Retro

John Hefter, November, 2005

Building a modern home theater in a classic home doesn't mean you have to go retro. You just need a little advice and some solid solutions.

S2 Media ArmoireTechnological design reflects the style of the times. And if a picture says a thousand words, the one above tells the story of the '50s, when brown and green were the colors du jour and television was not advanced enough to be flexible. The word "appliance" had just become a household term, and the novelty of home appliances made their unwieldy dimensions permissible.

Read Full article here.



 
 Home Entertainment

Finishing Touches
Neehi
Lean, Clean and Green
"De" Schofield
11/01/2005

Courtesy of Green Design

Lean, Clean and Green

The enduring appeal of Arts and Crafts-styled furniture resonates from its pure, clean-lined aesthetic—which has become a Green Design philosophy. As one of the leading creators of Arts and Crafts furniture, Green Design takes a prescient, iconoclastic approach to artisan workmanship.
 
“Our goal was to figure out what would happen if we approached the design and crafting as if the rules of convention were no longer in effect,” says founder/inventor Douglas Green of his 11-year-old enterprise in Portland, Maine. That unconventional philosophy led to the design for the Neehi Media Console, an all-in-one package available in three sizes—55, 72, and 84 inches long—to accommodate the full range of plasma, LCD, and thin-profile rear-projection TV screens.
Baffled that display options had not kept pace with the proliferation of flat-screen TVs that have flooded the marketplace, Green had an epiphany, which became his mission statement. Today, his beautiful, eco-friendly Neehi—which is handcrafted in sustainably harvested American cherry wood—places the center of the screen at eye level for ideal viewing, manages to store the accompanying components, and provides intelligent wire management and access through its installer-friendly, removable back panels and ventilated shelves. Optional features include open shelving or doors with wood or textured water-glass panels, and a choice of vented or solid cherry adjustable shelves. The two larger sizes can be outfitted with a center speaker shelf and/or drawers.
 
Building upon an Arts and Crafts tradition, Green Design produces less than 1,000 pieces of furniture per year. The Neehi Console is now the most successful product in the company’s history. Price: $6,950, as shown in solid American cherry wood with wood or glass doors, four shelves, and two drawers (800.853.4234 or www.greendesigns.com)

 

 Home Entertainment

Drawing on the creative side of Maine
By TUX TURKEL, Portland Press Herald Writer

An industrial designer in New York City, Douglas Green could have picked almost anywhere to start his own furniture manufacturing business. Without a second thought, he chose Maine.
Full Article here.

Green Design Neehi Collection - a Home Theater Treasure

May 2005 - Green Design Furniture just announced the new Neehi Collection, created for thin-profile television owners in search of a media console that is both elegant and efficient. The single most successful product introduction in Green Design's history, the Neehi media console has set a new standard for flat screen home theater displays.

"Douglas Green has raised the bar by creating a brand new category of intelligent yet elegant flat screen TV displays," says Steve Hayes, former president of the Custom Electronic Design & Installation Association, and Owner of Maine-based Custom Electronics. Full article here.

2005 Governor's Award for Business Excellence

Gov. John E. Baldacci presented the 2005 Governor's Award for Business Excellence to Green Design Furniture.

 


Green Design Furniture was featured on HGTV! You can check out a QuickTime clip of the show by clicking on of these links:

Bigger Version (14.4MB)
Smaller Version (5.5MB)

Don't have QuickTime? You can download a free version here.


Home Theater, September 2004
Coming Attractions


When you combine a man's love for furniture and his love for high-end components, you get green Designs new S2 Media Armoire, from furniture designer Douglas Green. The solid cherry cabinet has removable back panels, so you can ire your system in place. The strategically placed holes inside the cabinet keep the wires nice and tidy, while adjustable shelves on movable slats provide ventilation for your components. The $7,680 unit measures 64 inches high by 55 wide by 28 deep and will complement any home theater.
Green Design Furniture

- Coming Attractions-"Green Design Furniture," Home Theater, September 2004

Inspired House, August 2004 -
The Lowdown on Platform Beds
by Maria Lapiana

Cool and close to the floor, the mattress on a platform bed is firmly supported by the bed's frame instead of a box spring. It's a low, lean, sophisticated look... The S2 platform bed from Green Design is based on a Japanese design, with a difference, says owner and designer Doug Green. "In a Japanese house, the bed is right on the floor. By lifting it up, and giving it a surround, it's a way of creating a pedestal for the bed. It makes it a place of honor."

-"The Lowdown on Platform Beds," Inspired House, July/August 2004

 

Wyoming Homes and Living Magazine, June 2004
Products page


The company's new Series2 (S2) collection combines added function with gently curving lines for a lighter, more contemporary look. This bed incorporates elements of conventional and platform designs. The mattress rests on ash slats below the surrounding cherry ledge to create a lighter, floating profile. The headboard is angled at the ideal pitch for reading.

- PRODUCTS-"Green Design Furniture S2 Platform Bed," Wyoming Homes and Living Magazine, May/June 2004

 

European Homes & Gardens, May/June 2004
Finds

Green with Envy
Most people might not consider the pieces of furniture pieces of art, but the makers of Green Design furniture would beg to differ. One of the few artisan furniture manufactures in the U.S., Green Design builds furniture on the tradition that began in the Arts and Crafts movement and hand crafts black cherry board into unique pieces with contemporary flair.. 1. Sideboard Table (40"H x 60"L x 18"D) with three drawers and two frame and panel drawers. 2. Petite Armoire (34"H x 39"L x 21"D) with two adjustable shelves for extra storage. 3. Demi Armoire (50"H x 39"L x 21"D) with water textured glass doors.

-finds- European Homes & Gardens, "European Homes
& Gardens, May/June 2004

 

Period Homes, Spring 2004
Custom Artwork & Furnishings

Manufacturer of Arts & Crafts-style furniture in solid cherry: beds, desks, chairs, sofas, end tables & a full line of office furniture; using sliding dovetail joinery.

-CUSTOM ARTWORK & FURNISHINGS-Period Homes, Spring 2004

 

The Audiophile Voice, Vol.9, No. 6
New Products

The Green Design S2 Audio Cabinet is perhaps the very most elegant solution for those with sufficient taste to appreciate the fact that new, custom-made audio furniture can both do its job and not look out of place next to period Stickley antiques. The Green S2 Audio Cabinet is truly made to fine furniture standards yet it solves the problem faced by many interior designers, lots of vertical space and insufficient horizontal area. This graceful design (and its companion S2 Media Armoire) offers convenient, removable back panels, wiring accommodation, six adjustable shelves (five shown), and is either vented or solid. The owner may choose either solid-wood frame-and-panel doors or rippled, water-textured glass doors. Related furniture includes loveseat, armchair, S2 coffee table, sofa, and étagères. Dimensions are 55.5 H by 30 W by 24D.

- NEW PRODUCTS,-"The Green Design S2 Audio Cabinet," The Audiophile Voice, Vol. 9 Issue 6

 

Connected Home Magazine, April 2004
The Home By Design Furniture:
An interview with Doug Green

axm, April 2002
American Classics

Once in a while someone or something comes along that sets the trend others have to follow. Green Design Furniture is one such company that has set new standards in furniture design writes Paul Disney.

Tucked away in Portland, Maine, USA must be one of the best kept secrets state side of the Atlantic. Green Design Furniture, a small artisan furniture making company is producing some of the finest furniture that I have seen for some time. Crafted in Cherry Wood, the 'Series 2 Designs collection' takes its cue from Far Eastern architecture and decorative arts. The whole concept uses the Arts and Crafts style of the late nineteen—early 20th century and the furniture literally speaks for itself.

Doug Green, designer and founder of the company says the secret of its success lies in his acknowledgment of 'what relevant design tradition is in the 21st century.' He said: 'When you look at the history of the American decorative arts, especially furniture design, there is an especially strong link between technological innovation and the emergence of new styles and movements...In our times it is also quite true that mass production manufacturers have turned their back on the tradition of craftsmanship and lost any connection to values of authenticity in materials and design.'

What he refers to is furniture built in the 'American traditional style.' The invention that is the structure for every piece of furniture produced by Green Design Furniture, a patented method of construction that dispenses with the need for any metal or plastic fasteners. All of the components slide and lock together using a series of engineered and crafted sliding dovetails that are integrated into the designs. So another influence is the construction method itself, which creates a kind of visual design vocabulary.

The 'Series 2 Designs collection' reflects an exploration of form and content. Together combining function with gently curved lines to create a lighter more contemporary look. 'You could say I'm a big fan of Japanese design, but my American roots are usually showing,' says a very talented Doug Green.

Download the PDF (2.8MB). Need the free Adobe Acrobat Reader? Get it here.

For those who appreciate the artisan tradition and the value of inspired design, Green Design is a company you should definitely investigate. This superbly crafted furniture made of beautiful cherry wood is also innovative in its engineering. The furniture is shipped unassembled via Fed Ex and requires no tools, no glue and no fasteners. The components fit precisely and lock easily into a solid structure. A fascination with the form and functionality of traditional Japanese wood joinery and a cramped NYC apartment provided the inspiration for this furniture created by designer Douglas Green. Especially intriguing are his side chairs, with a sliding lumbar support that adjusts to the shape of your spine, a truly comfortable chair for lingering at the dining room table. In addition to chairs, there are tables, desks, beds, sofas, bookcases, bureaus and more. Its simplicity and elegance are reminiscent of the Arts and Crafts movement as well as Japanese design.

-"Homing in... Architectural Digest Home Design Show," The Home Monthly, June 2004

An industrial designer in New York City, Douglas Green could have picked almost anywhere to start his own furniture manufacturing business. Without a second thought, he chose Maine.

Green, a Bowdoin College graduate, felt that Maine had a critical mass of talented craftspeople, as well as a reputation for workmanship and creative freedom. In 1994, he opened Green Design Furniture on Portland's Commercial Street.

Today, Green has 14 employees and an expanding business that sells $4,000 dining room tables mostly to out-of-state customers. His business isn't unusual in Maine, Green said, just under-appreciated.

"Entrepreneurial life in Maine is vibrant, but not organized," he said. We don't have lobbyists."

Green and those who say artists, designers and other creative professionals can make a larger contribution to Maine's economic health will have a forum this week in Lewiston, at the first Blaine House Conference on Maine's Creative economy.

Green is scheduled to serve on one of the panels. A goal of the conference is to acknowledge and examine the factors that draw creative people to a place because that's where they want to live, not because there are specific jobs available...

At Green Design Furniture, Douglas Green said the conference is coming at the right time. There's a growing backlash by consumers, he feels, to the flood of inexpensive, low-quality merchandise found at major retailers. The artisans and designers in Maine can tap into that trend.

Green said he would like to see state government invest more in helping these businesses grow, as opposed to providing tax incentives to corporations that take much of their profits out of state.

Green Design Furniture has outgrown its 9,000 square feet of leased manufacturing space. Green said he plans to move to a new factory in the Portland area in the next year or so.

The creative economy conference, he said, may help raise the profile of successful businesses like his and what they need to grow.

"It's a wise thing to be looking at this aspect of the economy," he said. "It's a natural fit for what's here already."

- Tux Turkel, "Drawing on the creative side of Maine," Maine Sunday Telegram, May 2, 2004

PORTLAND, ME-Celebrated Maine furniture designer, Douglas Green, has created the S2 Audio Cabinet, in solid cherry, for those who have more vertical space than horizontal using the removable back panels, wiring and vented shelving features used in all of the S2 Entertainment Collection. Also available is the S2 Media Armoire, which has slide-away door panels that echo the graceful curves of the cabinet's top. It is spacious and sturdy enough to accommodate a 235-lb 36-inch television.

- ARCHITECTRONICS MODULE-"Green Design Furniture Targets Custom Market," Residential Systems, April 2004

Green Design's Classic Desk, S2 side chair, and four-drawer file cabinet are wonderful examples of the fine craftsmanship you should expect from high-end office furniture.

- Michael Brown, "Work surfaces: The word 'desk' is just too confining for this burgeoning category of office furniture," Home Computing, Issue 4, 2003

Prefer your TV not in view when not in use? Green Design's Series 2 media armoire can keep it out of sight, but the beautifully finished solid cherrywood cabinet may catch your eye anyway. The top part can hold most 36-inch direct-view TVs, and the lower shelves are adjustable for the height of your gear. There are openings for internal wiring, and the back panels detach in case you need to make way for a tangle of cables out to your receiver. You can pick doors to suit your room: solid wood or rippled water-textured glass. Overall dimensions are 55 x 64 x 28 inches.

-NEW PRODUCTS, Sound & Vision, June 2002

I love all the collateral materials I've ever seen done for Green Design Furniture. They all tie together nicely and create a great brand identity that goes hand in hand with this artsy furniture company; nicely lit photos show their product in the best light.

- Amy Barnes, "Top 100 Websites in Maine," Portland Monthly Magazine, May 2002

 

FURNITURE FOR A NEW FRONTIER - Green Design Furniture breaks all the rules by combining traditional craftsmanship with new cutting-edge technologies. Doug Green, owner and designer of the Portland-based company, makes no apologies that his furniture is not painstakingly labored over by hand, using the same tried-and-true woodworking practices performed by our forefathers. Not only is he proud of the design pieces he sells and stands behind the quality of his products, but Green also celebrates the fact that his furniture is made using innovative, modern technologies.

Before opening Green Design in 1994, Doug was an industrial design consultant in New York City. He earned his Master's degree in industrial design from Pratt Institute in Brooklyn, N.Y. Prior to that he studied English and art history and worked as a cabinet maker and furniture designer. Drawing upon his diverse academic and professional experiences, Doug was inspired to develop and patent a unique method of manufacturing furniture that employs a system of interlocking joinery that eliminates the use of any type of screws, nuts or bolts.

"I patented a system of assembling furniture without the use of fasteners or tools or any secondary devices," says Green. "It's a precisely machined system of interlocking joints, so that they won't work loose over time."

Green Design Furniture stands out, thanks to its innovative manufacturing process and unique design. A piece by Green Design also draws attention, because it is delivered in a box by Federal Express-and the customer completes the final assembly. It's a method unheard of in the world of upscale furniture, defying the long-held notion that fine furniture can only come pre-constructed and put together by a master craftsman.

Assembling a new piece of Green Design furniture is an easy process in which each new component secures the piece inserted before, and the final piece locks it all into place.

"As an invention, it's a really interesting thing," says Green. We're combining high-end beautifully finished and crafted furniture, with low-end, buy-it-in-a-box, bring-it-home and put-it-together-yourself furniture."

Green Design has approximately 80 pieces of furniture in its line. The most popular single piece of furniture is a solid wood computer desk, designed with optimum functionality and a 46" wide sliding tray. Only about 10% of the company's business comes from Maine, with the rest from out-of-state residential sales. According to Green, about half of the company's customer base is made up of repeat customers, many of whom are collectors of Green Design furniture.

Green chose to leave New York and start his business in Portland because he respected and admired Mainers' sense of independence and non-conformist attitude. "Maine is a wonderful environment for entrepreneurs," he says. "You have a lot of lateral freedom, and not a lot of obstacles here. The greatest asset is the people. They are collaborative and interested.

"There is also a great infrastructure for consultants, and people who are knowledgeable. I'm able to access a lot of talented people, in terms of management problems and all the different issues of growth."

- Donna Gaspar Jarvis, "Furniture with an Attitude," Port City Life, March-April 2002

PORTLAND, MAINE - Engaged in a quiet revolution, inventor and designer Douglas Green is introducing a new line of home furniture. Strong words to describe the graceful, elegant lines and meticulous finish of these pieces. But the reference is to a rebellion against conformity - and an affinity with the intention behind the Arts and Crafts movement that spanned the turn of the last century.

Series 2 represents an evolution from Green Design's earlier Mission-inspired designs into a new territory. As Stickley, Mackintosh and Frank Lloyd Wright did in their time, Green advances the tradition of embracing current technology, while reflecting contemporary culture in his designs.

Green continues to explore the essence of function, yet his forms are softer, lighter, more curvaceous. The S2 line evokes a more feminine quality, epitomized by the new bed. It's one of the pieces I'm most excited about," said Green. "For me, it's what a bed should look like in the 21st century."

The S2 bed is a hybrid of conventional and platform designs. The mattress and surrounding cherry ledge give the impression of a bed floating above the floor. The headboard is angled at the ideal pitch for reading.

The Series2 dining table features a gently curved top with a beautifully sweeping undercut edge. New dining chairs actively flex to conform to the spine's natural curve - offering the kind of comfort rarely experienced in a straight backed chair.

Green Design has responded to requests for an entertainment unit worthy of high-end electronics. The media armoire features slide-away doors with rounded panels that echo the graceful curves of the cabinet's top. It's spacious and sturdy enough to accommodate a 235-pound 36-inch television. Those who prefer to place their TV on a pedestal can choose the S2 Audio Cabinet. Both pieces provide ample room for electronic components, including the stretch 400 CD multi-disc changer.

Green Design Furniture's Series 2 also includes collection of occasional tables for the bedroom, hall, [and] living room, and new computer desks for [the] home office.

- "New furniture line unveiled for century," Longmont Daily Times, July 14, 2001

In 1993, we introduced the first furniture designs featuring the new assembly system at the International Contemporary Furniture Fair in NYC. Then, the goal was to find companies who would license the idea for their manufacturing. We received a good deal of attention in the trade press, but the most exciting of all was to be included in Time Magazine’s list for the best designs of the year.

Time Magazine, January 1993
The Best Design of 1993

Douglas Green: ETA Furniture
ETA stands for easy to assemble,: and it is, since Green, a Maine-based designer-craftsman, has conceived, refined and started manufacturing the Arts and Craftsy pieces himself. They come in kits and are made of solid cherry wood, not veneer. The component timbers are precisely slotted and notched to fit without nails, screws or glue. In each instance, the final component-for instance, the top of the dining table- acts as a keystone to hold the item together. It's the 1990's ideal: classic, ingenious, unpretentious, real.



This piece by Ann De Forest is one of the best ‘in-a-nutshell’ descriptions of Green Design’s approach to designing and making furniture.

US Airways Attaché, March 2000
Lo-Tech, Hi-Tech Joint Venture, Ann De Forest

Douglas Green's design mantra may echo the sentiments of Henry Thoreau: Simplify, simplify. And his furniture, with its clean lines, tapered silhouettes, and warm, rich wood surfaces, may evoke such Arts and Crafts icons as Stickley, the Shakers, and Charles Rennie Mackintosh. But Green, a cabinetmaker with a degree in industrial design from Brooklyn_s Pratt Institute, is not your retro rustic woodworker. His furniture, for all its craftsman's candor, hides a distinctive, hi-tech pedigree.

Green's designs spring not from his commitment to beautiful woodwork, but from his search for a more efficient, cost effective method of furniture manufacture an a mass- production scale. He discovered computer-driven routers, that is machining centers capable of performing incredibly intricate tasks over and over again. So what intricate task did Green decide to have the computer perform? He chose the workworker's challenge and mark of fine craftsmanship: the sliding dovetail joint. In the structural system Green developed, the furniture pieces fit together, he says, like a Chinese puzzle box. No screws or hardware are required for assembly; each piece interlocks with the next.

Unable to convince major furniture manufacturers to shift their paradigm, Green decided to go into the furniture-making business himself in a more traditional crafts production shop He had to engineer backwards, and adapt his designs to smaller machines and the human hand.

Still the basic premise of Green Design Furniture--the Chinese puzzle-box assembly--remains unchanged, and final assembly is left to the purchaser. The finished chairs, tables, desks, bureaus, and credenzas are shipped flat vialFedEx. We're the first and only manufacturer of high-end furniture what can get a product into people's homes in two days, boasts Green.

Green calls his approach craftsman programming--an oxymoron, perhaps, to those who view hand vs. machine as an ideological battle. But Green, who is as comfortable working in front of a computer as he is sanding a tabletop by hand, refuses to be drawn into that conflict: In today's world, with hand labor being as expensive as it is, if a machine can do something beautifully, why not let it? And while Green is quick to tout his method's revolutionary potential, he also sees his work a part of a long tradition of American craftsmanship, a tradition defined by invention.

For a profile of Doug’s career, this article by Peter J. Stephano is probably the best yet.

Better Home and Gardens Wood Magazine, March 2000, Peter J. Stephano
Furniture Designs to Go

Inside the meticulously preserved, 130-year-old brick building on Portland Maine’s waterfront, there’s a showroom full of solid cherry furniture. Its beauty is captivating. But its joinery is genuinely ingenious. Shoppers in Green Design Furniture’s gallery-like space admire the dining tables, chests, chairs, computer desks, beds, and bookcases made from rich lustrous wood. The lines of the pieces look contemporary, yet somehow appealingly familiar. None of the showroom’s visitors, through, realize from their first encounter that most of the furniture before them easily disassembles to lie flat in a box for shipping or moving. Until they're informed, they see nothing of the line's unique, patented, fastenerless joinery system that makes quick take down an assembly possible. But to Doug Green, the innovative woodworker who created the pieces and their means of joinery, that's the mark of good design.

From woodworker to industrial design; a path of creativity

"I realized only fairly recently that before I was a veer a woodworker, I was an inventor,” says Doug Green, the founder and head of Green Design Furniture. As a kid in Scarsdale, NY, he regularly took things apart and reassembled them in different form. He was a born tinkerer.

"I went to college right here in Maine,” Doug continues, "then I taught preschool. But I got caught up in the handcrafts movement of the late 1970's. And as a hobby, I began woodworking..."

After two years of teaching, Doug got completely hooked on woodworking, bought a full line of tools, quit teaching and opened a little shop in Topsham, Maine. "I was doing custom furniture and repairs, ad did it two or three years before getting a job as a cabinetmaker with Thos. Moser," recalls Doug. "At that time he had six cabinetmakers, up in the old Grange Hall in New Gloucester. Each cabinetmaker was completely responsible for a piece of furniture--a great learning experience for me."

Doug worked for Moser for a year, and during that time followed his natural inclination to find better ways to do something by designing jigs that sped up a process or refined it. "It was fun, finding more efficient ways of doing things," he says. This phase of Doug’s career would soon end, though, (as he) enrolled in the graduate program for industrial design at The Pratt Institute in Brooklyn, New York.

A look at the world through designing eyes

Pratt Institute’s industrial design program was nuts and bolts, according to Doug. It blended current manufacturing technology with creativity to arrive at a product. It was about materials and processes and how things were made in the world-- and conceptual problem solving.

“As an industrial designer, you have to have the freedom to question things,” Doug explains. “Sometimes, when you become too expert in a field of knowledge, your expertise limits your ability to ask questions and to innovate. At Pratt, I was taught to become a generalist.”

Easy-to-assemble furniture goes to the patent office

In the late 1980’s Doug began sketching an idea for a take-apart sofa made of the fewest possible components. It also had to be lightweight and easily assembled and disassembled. In 1989, he started prototyping his idea, but in chair form.

Doug experimented with many types of joinery, and finally decided on the sliding dovetail as the key. “I took me a long time to figure out how to do the long, tapered dovetails that enable the pars of a piece of furniture to interlock,” he says. “When I finally got the chair done, it was a creaky and unattractive piece of furniture with Baltic-birch plywood sides, seat and back. Everybody who saw it thought that it was a very strange looking piece of furniture, and it was. Yet, the joinery technique worked.”

Driven with the idea, Doug went to work making furniture with the dovetail joinery. He made everything-tables, case pieces and desks. By the time Doug was finished, he had 15 pieces of furniture.

“I’d also started working with a brilliant patent lawyer, Abbot Spear, a then 87-year-old Maine attorney. He came out of retirement to work on the project,” Doug comments. “He filed a patent for me in 1992 that 30 claims for creating different structures using the sliding dovetail as interlocking joinery, and it was awarded in 1995. The reason that it is a patentable idea was that during the patent search, we found out that the field of self-assembling, or fastener-free, furniture was all tab-and-slot, puzzle-type furniture. Mine was the first where joinery was part of the furniture, and it wants visible when the piece was assembled. The patent involved the order in which the pieces went together, too. So it’s not the sliding dovetail that’s patented, it’s how you create the structures.

“My idea was to get a patent on the process, then license it to a big furniture manufacturer and get a realty from every piece of furniture of my design that they sold.” Doug continues. “My patent-applied for furniture and I got a lot of attention in 1993. Then, I painfully realized that the furniture industry as a whole isn’t real progressive in terms of design. As a result, I had this great idea, and not one seemed to want it because it would involver restructuring how they make furniture. One CEO told me that they couldn’t keep their machinery accurate enough to produce the precision needed in my furniture, and they doubted that they could train their workers either.”

The birth of a business: Green Design Furniture

Doug did have offers from large furniture companies to buy his design outright, but after working on it for three years, he wasn’t about to give it away. So Green Design Furniture was born.

“Looking back on what’s happened, it’s like this idea had a will-a mind of its own,” says Doug. “This space [a former pottery factory] became the company’s first store. The furniture I built with the help of one other guy in a little shop in Brunswick, Maine. That was in 1994. Now I have nine [eleven as of 2002] people in the production shop. Today, about 80% of Green Design Furniture’s business comes via its catalog, which customers order from advertisements in the New Yorker magazine and the Wall Street Journal newspaper. At this writing, the company’s mailing list contained 30,000 names. “Last year, 35% of the people who ordered from us the first time, placed a second order,” Doug says. “ A typical first-time order is one piece, but we have people who order $10,000 to $12,000 worth of furniture at a time. A lot of that happens on the second or third order”.

There’s a definite customer service aspect to this type of business, too, according to Doug. “Because our furniture is shipped unassembled, it can go by Federal Express fast and at a reasonable cost to the customer. For example, we got a call this morning from a woman in Chicago who ordered and eight-drawer dresser. We can put that on the Fed Ex truck today, and it will get to her in two days from now. And with conventional furniture and freight, there’s a 24% chance that it will be damaged before it gets to the customer.
We have less than one percent damage. And the furniture doesn't seem to be bothered by humidity changes. I don’t know whether it the built-in tolerances, the cherry wood that all moves at the same rate, or the joinery, but we don’t have trouble.”

And because the customers handle each component in assembly, there’s nowhere to hide anything less than the best, even to the inside of a drawer. That’s why the craftsmen at Green Design Furniture must keep the quality level high, from the wood to the joinery, to the finish. Doug explains: “We’re such a micro dot on the radar screen nationally, our reputation for quality and customer satisfaction is of major importance.”

Inside the shop, furniture components travel on wheels

Although Doug’s furniture prototypes were done in ash, maple, cherry, and white oak, Green Design Furniture now produces-except by special order-only in cherry.

Unlike any shop that builds furniture in batches, at Green Design you’ll never see it (except for straight-backed chairs) being assembled until just prior to shipping. Because Doug has designed the furniture to assemble without fasteners, the components, such as table-leg assemblies and tops, can be shaped, joined, sanded, and finished individually. And the parts travel from work station to work station on carts. At shipping time, workers test-fit a furniture piece’s components, make any necessary corrections, then disassemble them and wrap for shipment.

When we set up a production run, we do the setup for each pattern. When we get the fit, we then can run all the pieces,” says Doug. “Making furniture this way combines traditional woodworking with this machining process. Part of each production run is building components: ripping, planning, jointing, edge-joining-getting them to uniform dimensions. When the components are done, we start the machining of mortises and tenons, and routing the dovetails.”

It’s the dovetails that prove critical. “The engineering for the sliding dovetail is difficult because it’s tapered,” Doug says. “That means that it’s wider at the back and narrower at the front, so that it locks when fully joined. We cut the female dovetail, which opens five thousandths of an inch-little more than a hair- at an inverted pin router to match the male tapered dovetail. I have designed three differed router tables to make the male dovetails with accuracy. What we are using is the third generation.

“Basically, it’s a pattern router with a linear motion bearing,” he adds. “It’s a precursor to a CNC [computer numerical control] machine that we’ll design someday to do the male dovetail with perfect accuracy. Until then we’ve been able to closely simulate CNC technology manually.”

There’s little doubt that Doug Green will in the future have a CNC machine of his design. With childhood heroes like Henry Ford and Thomas Edison, it’s a little wonder that his greatest pride comes from his furniture’s patent credit. That reads, “ Douglas Green, Inventor.”



I am very proud of PC World’s assessment of our Geek Factor. I didn’t even know we had one until this came out.

PC World, December 2000, by Michael Lasky and Dennis O’Reilly

A Few of Our Favorite Things

Elegance and Function for the Office

Constructed of high-quality solid mid-Atlantic cherry wood, Green Designs’ pricey computer desk dares to combine elegance and ergonomic functionality. The Green Designs desk arrives unassembled, but putting it together is simple and fun. Most desks consist of particleboard and screws, but this artisan-crafted furniture uses interlocking joinery in the hardwood, so its five components fit together in minutes, much like a jigsaw puzzle. It’s the first all-wood desk to have a full-length 45-inch sliding tray for a keyboard, mouse, and papers. You can easily tuck computer cables into an opening in the to of the desk, where they’re held in place with walnut covers. Beneath the desk, brass clips help organize the cables. Sure it’s pricey, but show us any last-a-lifetime art that isn’t.

What’s hot: Beautifully crafted ergonomic computer desk is functional art
What’s not: Extravagantly priced.
Geek Factor: Low



Ihave tremendous respect for this writer, Suzi Parker. After all, she has been the only reporter to notice my resemblance to a famous movie star. As a matter of fact, she’s the only person to notice this resemblance.

Special to The Christian Science Monitor, July 19, 2000, by Suzi Parker
Furniture you put together in a snap

Heirloom-quality pieces are shipped for you to assemble
PORTLAND, MAINE

On a typical Sunday afternoon, Doug Green can be found sanding furniture in his workshop, a few blocks from his spacious showroom near Portland's waterfront. A few years ago, Mr. Green packed up his bags, locked up his New York City apartment, and opened Green Design here. He had an idea: Make high-end wooden furniture that snapped together like jigsaw puzzles and could be shipped via Federal Express to the young modern on the go.

His idea worked. Today, Green ships out Arts and Crafts mission-style tables, computer desks, beds, bookcases, and sofas that can be assembled and dissembled in a matter of minutes.

"I want people to see furniture as an investment," says Green, who slightly resembles a younger Richard Gere. "I also want them to be able to keep a piece forever - an heirloom. Furniture isn't made like that much anymore."

Indeed, most modern furniture has screws, nuts, bolts, and glue that can weaken as years pass. It's hard for one person to pack it up and move it from coast to coast. But not Green's designs. He patented a method of manufacturing that utilizes the strength of the wood to hold the piece together. This system of interlocking joinery allows parts to slide and lock into each other. They can be packed flat and shipped almost as easily as an airline ticket.

Ten years ago, he was living in New York, using his bed as a couch. An industrial designer with a penchant for woodworking, he wondered if there was a way to make a couch that saved space and was easy to transport.

That's when he began experimenting with prototypes that had sliding dovetail joints. One day, after many tries, he succeeded.

"My designs worked, but I knew that to start a business I didn't need to be in New York," says Green.

He headed to Maine, where he had worked as a cabinetmaker years earlier. He chose Portland because of its history and attitude.

"This harsh climate has attracted gritty nonconformists for years," says Green. "I knew I could get a good pool of people to work here. There's a creative freedom here for people who want to do their own things."

He opened his business on the waterfront, which was shabby and run-down just six years ago. Today, the area surrounding Green's showroom hosts funky antique shops, eclectic bistros, and designer boutiques.

In his showroom office, Green designs all of the furniture. Each piece is then handmade from Pennsylvania cherry wood. A perfectionist, he hires people with little woodworking experience because he wants to train them in his own methods.

He employs about 15 people; the average employee is 24 and has a college degree. In the workshop, associates - as Green likes to call his employees - listen to punk band Siouxsie and the Banshees, jazz great Charlie Parker, and Irish band U2 while turning cherry wood into quality works of art for customers across the country.

Fifty percent of Green's business comes from the West Coast. More than 47 percent of his customers are repeat buyers. And at least 85 percent of purchasers buy the furniture from the catalog or Web site (www.greendesigns.com).

This fall, Green will unveil two new dining-room tables. He expects them to be popular, but no piece, he says, can compare to the best-selling computer desk.

"If you are going to sit at a desk all day, and sometimes all night, you better like that piece of furniture," says Green.

His computer desk is clean in design and functional. It features a 45-inch sliding tray for keyboard, mouse, and papers. Computer cables run through precision-cut openings in the top. It, too, boxes up and can be shipped overnight.

This Japanese-influenced furniture isn't cheap. The desk costs about $2,500 before shipping. A king-size bed runs $2,775, plus $300 for Fed Ex delivery. A solid cherry bench is $875.

When Green started producing his "jigsaw-puzzle furniture," he also began to design and fine-tune the manufacturing process. For the past six years, he and his crew have invented, fabricated, and perfected their own machines and production patterns.

The technique works. Last year, Green Designs was a million-dollar business.

"Our business has caught on," he says. "We now have a rhythm going, and it doesn't hurt that we have a great track record with customers."

Green signs the first 100 pieces of a line. His keen attention to detail and precision has earned him several prestigious design awards.

In 1993, he was selected one of the top designers of the year by Time Magazine.

In 1997, his designs received an award for "value and versatility" at the Philadelphia Fine Furniture Show.

And Green's work isn't just in homes. A Green hall table greets visitors in the Portland Museum of Art, which was designed by renowned architect I.M. Pei.

A senior partner at a Washington law firm noticed a small sketch of a table in the catalog. He called Green and asked if he could adapt the design into a 23 foot-long conference table. Green said yes and designed and delivered the table.

Buyers quickly recognize the quality of their purchases.

"The customer puts it together, so he will see every aspect of the furniture from the inside and outside," says Green, who has been known to toss aside a piece that isn't working.

"There's no fudging here. Every piece has to be perfect."

 

       
 

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