The Raw Materials
The life of a made-to-order upholstered piece begins with the raw materials, which are ready at the warehouse for each specific order. These include wood frames for sofas, chairs, benches, and headboards as well as foam and fabric bolts for upholstering the furniture. The essential parts are gathered and construction of the furniture begins after the order is received.
Next, fabric is pulled and brought to the cutting table (shown, left). Here, cutters follow a template and cut the fabric to size for each piece of furniture. The fabric is then handed to the sewing department. The sewers have precise patterns to follow, which ensures consistency.
Meanwhile, the wood frame for each piece is prepared with foam for upholstering, and the wood legs are stained. Once the fabric is ready from the sewer, it is brought to the upholsterer, who staples it in place.
If there is tufting on a piece of furniture, the sewers pass the fabric to tufters, who sew in the buttons and any other details by hand. Once the piece is completely upholstered, finishing touches like nail heads and welts are hand-applied, and the piece is packaged and shipped directly to the customer.