As the core furniture of the home, the sofa's production process combines traditional craftsmanship with modern technology, involving multiple processes such as woodworking, sewing, filling, and assembly. The following full process analysis from design to finished product, combined with industry standards and actual production experience, fully reveals the production process of sofas.
1. Design and proofing
The design of the sofa must take into account both aesthetics and functionality. In modern technology, 3D modeling tools (such as 3DMax, ZBrush) are often used for modeling simulation and size optimization to ensure structural rationality and comfort. The design drawings must clearly define the frame angle, filler distribution and fabric cutting plan. Some high-end brands will also conduct proofing verification based on ergonomic data.
2. Frame production
The frame is the "skeleton" of the sofa, which directly determines the load-bearing capacity and service life.
Material selection:
The main material is mostly Northeast dried birch (moisture content ≤12%), supplemented by high-density fiberboard or plywood, which has both moisture resistance and cost advantages.
Solid wood is used in key stress-bearing parts, and composite panels can be used in non-load-bearing areas.
Processing technology:
After the wood is polished on all four sides, it is connected by mortise and tenon technology. The interface is reinforced with a wooden tripod and fixed with glue and screws.
Some frames use springs (snake springs or independent cylinder springs) and rubber bands to enhance elasticity. The back frame is mainly bandages, and the seat frame requires a more complex spring system.
3. Filling layer production
The filling affects the sitting feel and durability of the sofa and needs to be processed in layers:
Base layer: high-density sponge (density ≥35kg/m³) is used for support, medium-density sponge (25-30kg/m³) is used for transition, and the surface is covered with down or artificial cotton to improve softness.
Cutting and fitting: The sponge is accurately cut according to the shape of the sofa. Complex curved surfaces need to be positioned using templates and fitted with the frame through adhesives.
4. Fabric cutting and sewing
Fabric selection:
High-end sofas mostly use European imported fabrics or natural leather, with color fastness ≥ level 4 and wear resistance better than industry standards.
Fabric sofas often use cotton and linen blends or flannel, which need to be pre-shrunk to avoid deformation.
Sewing process:
After cutting, use an electric high-speed flat-sewing machine from Taiwan Province of China for splicing. The seams need to be trimmed or pressed to ensure that the stitches are straight and wrinkle-free.
Leather sofas require additional processes such as ironing and peeling to eliminate the roughness of the leather edges.
V. Handcraft assembly
The key steps to fix the fabric and filling layer to the frame:
Cover: Use a horse nail gun or a straight nail gun to fix the bandage, gauze and sponge layer. The nail spacing must be uniform to avoid local looseness.
Fitting: The sewn coat is combined with the frame through a zipper or concealed button. Fabric sofas need to be installed with hardware (such as metal feet), and leather sofas need to be manually stretched to ensure flatness.
VI. Accessories and details
Hardware: The base needs to be galvanized/chrome-plated for rust prevention, and a rubber pad is added to the bottom; the zipper is a customized model to ensure smoothness and durability.
Environmental protection requirements: The adhesive must meet the water-based environmental protection standards, and the electroplated accessories use a cyanide-free process to reduce pollution.
VII. Quality Inspection and Packaging
Testing Standard: According to QB/T 1952.1-2023, the load-bearing, resilience, fabric color difference and hardware corrosion resistance are tested.
Packaging: The finished product is protected by transparent plastic film, cushioning cotton and woven bags to avoid transportation damage.
Purchase Notes
Material: Solid wood frame and high-density sponge are preferred to avoid odor of composite board or collapse of filling.
Process Details: Check whether the stitching is neat, whether the hardware is stable, and the cushion rebound time should be ≤5 seconds.
Through the above process, the production of sofas not only reflects the inheritance of traditional woodworking and sewing skills, but also integrates modern material science and ergonomic design, and finally achieves home products with both comfort and artistry.
