POLYWOOD has done something incredible for the outdoor furniture industry: they’ve made recycled HDPE poly lumber a household name. And for that, we tip our hats to them.
But here’s what most people don’t realize: POLYWOOD isn’t the only company making recycled plastic outdoor furniture. In fact, some manufacturers have been doing it even longer — with a very different approach.
If you’re shopping for POLYWOOD-style furniture but want something more personal, more customizable, or more unique, this guide is for you.
What Makes POLYWOOD Popular?
Let’s give credit where it’s due. POLYWOOD succeeds because they offer:
- Recycled HDPE poly lumber construction
- Wide color selection
- National distribution through major retailers
- Consistent quality across a massive product line
- Strong brand recognition
For many buyers, POLYWOOD is a perfectly good choice. But “perfectly good” isn’t the same as “perfect for you.”
Why Some Buyers Want an Alternative
We talk to POLYWOOD shoppers every week. Here are the most common reasons they’re looking elsewhere:
1. They Want Handcrafted, Not Factory-Made
POLYWOOD operates large-scale manufacturing facilities in Indiana and other locations. Their furniture is well-made, but it’s mass-produced on assembly lines. Some buyers want furniture that’s been touched by human hands — where a craftsperson took the time to inspect every joint, smooth every edge, and ensure every piece meets a personal standard of excellence.
2. They Want a Unique Story
There’s a difference between buying from a corporation and buying from a family. When you choose a family-owned manufacturer, you’re supporting real people — and getting furniture with a story you can tell your guests.
3. They Want Coastal-Proven Durability
Here’s something most people don’t consider: where your furniture is made and tested matters. Furniture designed and built on the coast — where salt air, hurricane winds, and intense UV are daily realities — is engineered differently than furniture made in the Midwest.
4. They Want Better Customer Service
Large companies have call centers. Small manufacturers have owners who answer the phone. When you need help choosing the right dining set for your space, would you rather talk to a customer service representative reading a script, or a furniture maker who’s been doing this for 35+ years?
5. They Want Different Design Options
POLYWOOD offers a specific aesthetic — clean, modern, and consistent. That’s great if it matches your style. But if you want something with more character — a deeper curve on your adirondack chair, a traditional high-back design, or a collection that feels more artisanal — you need to look beyond the big brands.
Carolina Casual: A POLYWOOD Alternative Since 1986
Carolina Casual has been handcrafting recycled outdoor furniture on the Outer Banks of North Carolina since 1986 — years before POLYWOOD entered the market. Here’s how we compare:
| Feature | POLYWOOD | Carolina Casual |
|---|---|---|
| Material | Recycled HDPE | 95% Post-Consumer Recycled HDPE |
| Manufacturing | Mass-produced, factory | Handcrafted by skilled artisans |
| Location | Indiana (headquarters) | Point Harbor, NC (Outer Banks) |
| Founded | 1990 | 1986 |
| Ownership | Corporate | Family-owned & operated |
| Color Options | 15+ colors | 15 custom colors |
| Hardware | Stainless steel | Marine-grade stainless steel |
| Design Style | Modern, streamlined | Classic & curved collections |
| Customization | Limited | Direct communication with makers |
| Coastal Tested | Lab tested | Built and tested in coastal environment |
| Buying Experience | Retail / online | Direct from the maker |
What Sets Handcrafted Apart
When we say “handcrafted,” we mean it. Every piece of Carolina Casual furniture is:
- Cut and assembled by experienced artisans in our North Carolina workshop
- Inspected individually — not spot-checked on a production line
- Built with marine-grade stainless steel hardware selected specifically for coastal environments
- Designed through decades of real-world testing in one of America’s harshest outdoor environments
The Outer Banks experiences salt spray, 100+ mph hurricane winds, intense summer UV, and nor’easter storms. Our furniture doesn’t just survive these conditions — it’s designed specifically for them.
Our Collections
OBX Curved Collection
Our signature line features a distinctive curved design that you won’t find from POLYWOOD. The ergonomic shape cradles your body naturally, and the curved lines add visual warmth that straight-edged furniture can’t match.
Available in: Adirondack chairs, rockers, loveseats, chaise lounges, bar chairs, counter chairs, dining chairs, swings, and tete-e-tetes
Traditional Collection
Clean, classic lines with high-back and low-back options. Traditional craftsmanship meets modern materials.
Available in: Dining chairs, club chairs, rockers, chaise lounges, benches, swings, and armless chairs
Waterview Collection
Our newest designs, featuring wide fan-back adirondack styling perfect for watching sunsets over the sound.
Available in: Adirondack chair and ottoman
Deep Seating Collection
Plush comfort with cushioned seating on recycled poly lumber frames.
Available in: Sofa, loveseat, chair, ottoman, coffee table, and end table
Complete Dining & Entertaining
Full range of tables from intimate 30″ squares to grand 100″ rail huggers, available at dining, counter, and bar heights.
The Real Cost Comparison
POLYWOOD and Carolina Casual are in similar price ranges. But consider the total value:
- Carolina Casual: Direct-from-maker pricing, personalized service, handcrafted attention to detail, coastal-proven engineering
- POLYWOOD: Retail markup through distributors, mass-production consistency, wider availability at big-box stores
When you buy direct from a family-owned manufacturer, you often get better value per dollar because there’s no retail middleman taking a cut.
Who Should Choose POLYWOOD?
To be fair, POLYWOOD is a great choice if you:
– Want to buy from a local big-box retailer and take furniture home today
– Prefer their specific modern design aesthetic
– Want the confidence of a nationally recognized brand name
– Need a very specific product they carry that we don’t
Who Should Choose Carolina Casual?
Carolina Casual is the better choice if you:
– Value handcrafted quality over mass production
– Want furniture proven in coastal environments
– Prefer buying direct from a family-owned maker
– Love our curved, traditional, or waterview designs
– Want a personal relationship with your furniture maker
– Care about supporting small American manufacturing
– Live on or near the coast (especially the Outer Banks!)
– Own a vacation rental and need furniture that survives real-world abuse
Ready to See the Difference?
We believe the best way to understand the difference between handcrafted and mass-produced is to see it — and sit in it — for yourself.
Have questions? We’d love to talk. Unlike big corporations, when you call us, you’ll talk to someone who actually builds the furniture.
Carolina Casual has been handcrafting recycled outdoor furniture on the Outer Banks of North Carolina since 1986. Every piece is made from 95% post-consumer recycled HDPE plastic and built to last a lifetime.