Sofa Construction 101– Learn the Art of Crafting Sofas from Frame to Finish

Sofa Construction 101– Learn the Art of Crafting Sofas from Frame to Finish

Sofa construction is an art that involves many stages. From sofa design, choosing material all through to the final product.

In this guide, we will demystify every stage and idea during the best sofa construction process.

Let’s dive right in:

Step 1: Start by Designing Sofa Sets

Before, making sofa sets, you must have an appropriate design. Of course, there are traditional and modern sofas. Besides, you can opt for any custom sofa design according to your unique specifications.

This is a critical stage since you will have all the vital sofa construction details. Therefore, in your sofa construction detail drawing, you must specify all parts alongside the required specifications.

The specification may include design, material type, and size. Again, from this, you can classify different types of sofa chairs.

Figure 1 Outdoor aluminum sofa

 

Sofa Parts Remarks
Couch back · Usually, we have the inner and outer back

· You can choose from a tight back, pillow back, or attached back

· These also form important sofa design parameter

Couch arms · Again, we have inside and outside arms

· Common arms include rolled arms, box arms, or English arm

Couch cushions · There are permanent or removable options

· This is where you will sit

Couch skirt · Common for sofas with the traditional look

· You can choose from loose, ruffled, or custom designs

Sofa Legs · They hold the entire sofa structure. Usually, they are in direct contact with the ground
Sofa Upholstery · It covers the entire furniture structure

· You can choose from leather or any form of fabric

Sofa metal frame · The frame is the skeleton or structure that holds other sofa parts
Spring for Sofa · Provide slight bounce, support cushion, and ensure comfort
Stuffing of padding for sofa · Usually, they are in the form of foam or spongy material

 

Note: These are some common parts of sofa designs. However, sofa sets may have hundreds of parts.

Some common types of sofa sets include:

Figure 2 Metal sofa furniture legs

Types of Sofa Sets Description
Standard Sofas · Common types and designs that offer varying levels of comfort

· They come in different configurations including fabric sofa sets, leatherette sofa sets, genuine leather sofa sets, etc.

Sofa bed or Divans · Known for its multi-purpose design

· Ideally, this is a sofa you can use as a bed

Recliner sofa sets · With these sofas, you can raise or lower both the back and front sections.

· They are known to offer more comfort

· Usually, there are automatic or manual recliner sofa sets

Corner sofas · As the name suggests, these sofas take the “L” shapes thereby fitting properly in corners.

 

When it comes to the sofa-making process, you can choose a full sofa set, a two-seater, or a love seat. Of course, there are modular options to choose from.

You may also consider other sizes such as deep seats. These sofa designs are suitable for tall people.

More importantly, the sofa set arms play a critical role during the classification process. They show artistic designs with unique statements.

Once you know the sofa set design and parts – go-ahead to design sofa sets. At this stage, you will have all the necessary sofa construction details ready for the next step.

Step 2: Choose Sofa Set Material

 

Figure 3 Sofa made from metal tubes

There are many furniture materials depending on the aesthetics and design. Remember, different furniture will require unique materials.

Take for example, for the best reclining sofa construction – you need metals for the reclining mechanism since they are durable.

Well, the type of material you choose at this stage will depend on your design specifications in Step 1 above.

Let’s look at some common sofa set materials:

Sofa Set Metal Frame Material

The sofa frame forms the primary structure of this furniture. The frame determines the shape, and strength of the furniture. Therefore, you must choose high-quality, durable, and reliable material for the sofa frame structure.

The most common sofa frame materials are:

Sofa Frame Material Remarks
Metal for Sofa Frame · Although metal is a strong option, it is always more expensive.

· In most cases, you can use metals such as aluminum, iron or stainless steel. For custom options, you may explore other types of metals.

· The metal frame for sofa should be easy to fabricate. Besides, the metal should be ready available

 

The material for the sofa frame will determine the sofa construction technique. Remember, metal by cutting, shaping, or polishing to get the right design.

Sofa Set Joint Material

 

Figure 4 Simple metal sofa

Joints are sections in sofa set that help in reinforcing the sofa frames. Looking at the sofa frame construction plan, you will see reinforcement structures in areas that are subjected to high stress.

The sofa reinforcement structures may range from screws, nuts, and rivets, just to mention a few.

Sofa Support Section

Another part that determines the sofa construction quality is the support area. You must choose an appropriate structure and material that will offer comfort and withstand the weight.

Remember, the support will also determine whether the sofa set design is durable or not. There are many options you can consider when making sofa sets such as:

Sofa Support System Remarks
Sofa Spring System · Springs are made from metal

· They come in different configurations

· Common designs include 8-way spring systems which are usually hand-tied, steel springs, coil spring assembly, etc.

· When choosing sofa springs, always consider the gauge

Sofa Lattice Web System/Webbing Seat Support · A common option in modern sofa sets

· They are mainly straps made from polypropylene material

· The webbing suspension forms a sofa cushion construction

 

Sofa Upholstery Material

In the sofa furniture making process, the term upholstery refers to the art of incorporating other sections such as:

  • Padding
  • Leather
  • Textile
  • Cushioning, or any other decorations

Now, depending on the type of sofa you want, there are many materials including leather, tartan, velvet, corduroy, etc.

For example, when choosing your best sofa cushion construction material, you may choose leather. On the other hand, another client may choose a textile. Usually, sofa cushions are made of materials such as cotton or polyester fiber.

The padding materials may include animal hair, polyester material, rubberized hair, etc.

Step 3: Sofa Set Fabrication Process

Once, you have the sofa construction drawings, materials, and equipment, it is now time to start the actual process. Depending on the technology, equipment, and sofa design, the duration may vary broadly.

However, Chinese furniture manufacturers guarantee fast turn-around time.

Ideally, the sofa manufacturing process involves 5 key stages. In each stage, you will transform the material into artistic sofa furniture depending on the technical drawing.

Let’s take a look:

1. Metal Framing for Sofa

The best sofa frame construction should consider the weight which the furniture will handle. It should be fully reinforced. Besides, the frame should be free from any defects that may compromise sofa furniture quality.

Figure 5 Sofa Technical Drawing

You will use frame sofa construction detail drawing, to cut and fabricate different materials. Here is how sofa frame construction works:

  • Understand the sofa frame structure plan according to the technical drawing. That is, you must visualize the plan on how you will fabricate each part and assemble it to make a complete sofa frame.
  • Cut sofa frame material to suitable dimensions and sizes. It involves cutting metal, bending metal, punching metal, drilling metal or forming metal to a suitable shape etc. Remember, there are many metal fabrication techniques.
  • Assemble various components to form a complete structure. You can weld, rivet, screw, or glue various sofa parts. Where necessary, add support systems and reinforcements to ensure the sofa is strong enough.

By the end of this process, you should have a complete sofa metal frame. You should inspect the sofa frame quality, as the next steps when making sofa furniture will depend on the frame.

A weak sofa frame implies low-quality furniture.

2. Webbing and Springs for Sofa

Next, you will include either webbing or springs on the sofa frame ready for the padding process. At this point, the main options are mainly sofa webbing vs spring construction.

Depending on the type of sofa furniture you want, you will install inter-woven strips across the sofa frame. At the same time, you can also include springs that can be installed within the frame.

Depending on the level of comfort you need, you can choose webbing or springs for the sofa. Alternatively, you can use both.

However, it is worth noting that sofas with springs offer better comfort. Usually, they allow for a bouncing motion when you sit on them. This is a different case with the sofas with webbing. Webbing is not as flexible as spring.

Once you install the webbing and springs on the sofa frame, it is now time for padding.

3. Sofa Padding Process

As you manufacture sofa sets, it is important to note that the structure may consist of multiple sections. Therefore, you will carry out the padding processes on different sections depending on the design you wish to make.

You will put and shape the padding material depending on the shape you wish to make. Some common materials include horsehair, high-resiliency foam, or any other synthetic material.

Usually, this is a critical stage as it determined the quality of stylish well-constructed sofas.

For example, you can loosely attach the padding material on the sofa frame. However, for a more defined structure, it is recommended to tightly stitch the padding material, dividing the furniture into different sections.

Note: You should cover all sections of the furniture including arms (when necessary). Additionally, it is essential to thoroughly inspect the sofa padding process to ensure that the surfaces have the desired shapes.

4. Put Sofa Fabric or Sofa Leather

 

Figure 6  Stylish sofa sets with metal frame

The sofa fabric or leather will give the furniture its final appearance. Usually, the fabric or leather comes as a large material. It is upon you to cut the material depending on the different sections of the sofa set.

It is important to cover all sections based on your design and stitch the material onto the padded sofa structure.

5. Finishing and Quality Control in Sofa Manufacturing

You will apply the necessary surface finish to add aesthetic value. Certain finishes increase the sofa metal material lifespan.

The best-constructed sofas must conform to safety and government regulations. Besides, once you construct a furniture sofa, you should subject it to various quality tests and evaluations.

Furniture quality testing ensures that all products meet the recommended safety guidelines. If possible, providing test reports, especially when exporting the furniture to other countries.

Note: These processes may vary depending on the type of sofa furniture you wish to construct. In most cases, your manufacturer can take you through a step-by-step process. That is, how they handle the entire process.

Conclusion

In short, sofa construction involves many steps as you can see above. In every stage, you must adhere to the intended dimensions to get the right shape and design of sofa sets.

DongRong is a trusted sofa supplier and fabricating company in China. For all your sofa imports from China, contact us now.

More Resources:

Sofa Frame and Support Construction – Source: Belfort Furniture

Sofa – Source: How Products are Made

Tips for Buying a Sofa – Source: Lamps Plus

Sofa Buying Guide – Source: Décor

Sofa Designs – Source: Regan

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