Inside Ikea’s dream factory: Its prototyping lab (exclusive)

We have the first-ever look inside the secretive Swedish facility, revealing how the world’s most popular furniture retailer mocks up and ultimately gut checks up to 2,000 new products a year.

The tiny easy chair Mikael Axelsson is holding in his hands—a dollhouse-size combination of bent wire, hand-carved foam, and hot glue—has been a white whale for the Ikea designer since he first modeled it back in 2014. The concept was simple, or at least he thought it would be: Build a frame of metal, fill it with a balloon-like cushion, and reinvent novelty 1990s blow-up furniture into a modern home furnishing. 

But after trying to take the Barbie-size model he’d built and expand it into a full-scale piece of inflatable furniture, he had two major problems. First, he could never quite figure out how to make an inflatable cushion that didn’t feel like an exercise ball.........

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