Blog Post - How we build a sofa

At Custom Furniture Design we manufacture upholstered furniture and our team have been crafting sofas for over 30 years.

Below is a snap shot into what’s involved in creating sofas, lounges, recliner suites, sofa bed as well as upholstered beds, ottomans and occasional chairs for homes in Australia.

What is the process?

1. Plan and Measure 

We start by determining the dimensions of your sofa. Measure the space where it will be placed and decide on the sofa’s height, depth, and width. Sketch a simple design, select from one of our existing designs, tweak our designs or come in with some pictures of what you desire.

2. Building the Frame 

Using your measurements, we cut the timber to create the base frame and backrest. Assemble the frame using a variety of methods including screws, staples and wood glue as well as adding supporting brackets and corner blocks for added stability. Ensure all corners are square and the frame is sturdy.

3. Add Support and Comfort 

To enhance comfort we add high quality webbing with a 10 year guarantee and secured it to the frame with staples. Over the webbing we add a layer of foam and fabric.

4. Fabric 

When the frame has been built we being to measure the frame to begin the fabric cutting phase. The fabric roll is laid out on our 15 mtr table and it’s marked out with patterns which will make up the body, cushions and arms of the sofa.

5. Sewing 

The fabric has now been cut and packed together to be transferred to our sewing machinist who being to sew the cushions and the body of the sofa for upholstery. In this section we add details such as piping to the upholstery in line with what the customer has ordered.

6. Prepare the Cushions 

Here we cut the foam to fit the base cushions and for the arms of the sofa. This is another area of customisation where customers can select from soft, medium, or firm foam density. Each cushion is cut to size and then wrapped in a later of dacron. This creates a smooth, cushioned surface that will enhance the sofa's comfort. Customers can also select feather cushions or have memory foam as an option to provide an even more luxurious feel.

7. Upholster the Sofa 

The timber frame is passed onto the upholsterer who will being to add foam to the body of the sofa, separating the final fabric and timber frame and they ensure it’s covered all areas of the sofa. They then begin to place the covers over the frame and foam stapling the fabric to the frame, starting from the centre and working outwards. They pull the fabric taut to avoid wrinkles and secure it with a staple gun.

8. Add Finishing Touches 

The feet are attached depending on the customers requirements. The sofas seat and back cushions are placed, it’s checked all over to ensure uniformity and we take a seat to ensure it’s comfortable.

9. Final Inspection 

The sofa is checked again for any loose threads. We then pack the sofa in plastic and place protection on arms for transportation and it’s loaded onto the truck for delivery.

10. Delivery day.

You receive the sofa and begin adding your own unique touches with throws and scatter cushions.

Conclusion

Building a sofa from scratch is a rewarding project that combines creativity and craftsmanship. A custom piece has been created that perfectly fits your home and style. We hope you have enjoyed the process and take pride in your new handmade sofa. We pride ourselves on creating a unique piece for your home.