How sofas are made

Some factory sofas are vacuum-squeezed to half their size so they fit in a shipping box.

stations: 7
things upstream: 63
raw sources: 17
steps from the ground: 9

The short version

A factory sofa starts as a frame of kiln-dried wood or MDF, glued and screwed together. Zigzag springs stretch across the seat, and foam goes on top. Fabric cut in stacks is sewn into covers, which are pulled tight over the padded frame and stapled. Legs go on last, followed by inspection and packing.

Build the wooden frame

Kiln-dried wood or MDF is cut by saws and CNC machines into arms, back and seat, then joined with screws and glue. Well-made frames add reinforced joints.

Goes in
Lumber MDF Adhesive
Stretch the seat springs

Springs go across the seat frame first and are pulled tight. Zigzag serpentine wires are common and cheap, and classic hand-tied coils are giving way to mechanically attached grids.

Goes in
Steel wire
Cut and layer the foam

Foam blocks are carved with hot wires or blades. Firm foam goes at the bottom for support, softer foam on top, and fiber or feathers can be added for softness.

Goes in
Polyurethane Polyester
Cut the cover fabric

Fabric is inspected and laid out in stacks up to 20 layers deep, then cut to patterns that leave few scraps.

Goes in
Cotton fabric
Sew the covers

Machines stitch the panels into fitted covers, with heavy-duty machines for thick leather seams.

Goes in
Sewing thread
Pull on the covers

Covers are pulled tight over the padded frame with no wrinkles, then fixed with staples or nails. Legs and any hardware go on next.
Inspect and pack

Inspectors check seams and sit-test the sofa. Packing adds foam corners and cardboard, and vacuum packing shrinks some sofas down to half size.

End of the lineSofa

Worth repeating

Hand-built sofas are an older craft: burlap, flax twine and tied coil springs, with thin rosewood layers glued cross-grain for carved Victorian backs.
Fabric for sofas can be cut up to 20 layers at a time.