Our Sofa Construction

Our sofas are built to offer lasting comfort for 5 years and more.

This is supported by partnership with quality focused factories and selective use of durable materials.

Sofa Construction Process

  • The cut solid wood are stapled together to form the sofa frame

    1 - Construcing the Frame

    Kiln dried solid larch wood is cut based on sofa dimensional. Screws and staples are used to connect the wooden pieces to form the frame. Corner blocks are added to enhance stability.

  • The zigzag springs and webbings are attached to the sofa frame as suspension

    2 - Installing Suspensions

    5mm thick carbon steel zigzag springs are installed to offer seat comfort. For a 2.0m 3 seater sofa, about 8 - 10 zigzag springs are used to act as support and evenly distribute weight on the sofa.

  • Foams are then added to the frame to form the seat and back cushions of the sofa

    3 - Making Cushions

    High density foams, polyester fibres and down feather are used to create the seat and back cushions. High density foams at least 11cm thick are used for seat cushions.

  • The fabric is cut based on sofa dimensions and then sewn together using Durkopp Adler sewing machines

    4 - Preparing the Upholstery

    Fabric or leather are cut and sewn together to form the sofa upholstery. The materials we chose are tested for durability by key testing agencies such as SGS, Intertek and CTi.

  • The sewn fabric are them stapled to the frame to form the upholstery of the sofa

    5 - Assembling and Cleaning

    Different sofa components made separately are assembled together to create the final product. Post assembly, it undergoes airjet cleaning process to remove dusts before packing.

  • Post assembly, the sofa is inspected for its dimensions

    6 - Inspection and Packing

    The completed sofa is inspected for dimensions, stitching, and upholstery mounting quality. They are then packed with at least three protective layers to prevent damage during shipping.

Our Past Sofa Constructions

Explore Our Sofas