Velvet Sofa Factory

Description

Our design team draws precise three-dimensional blueprints based on ergonomic principles and the spatial
layout requirements of the intended use scenario, ensuring the sofa strikes a balance between aesthetic
appeal and comfort.

To achieve this unique curved shape, the factory imports the design drawings into CNC cutting equipment,
which, under precise computer control, cuts a skeleton mold from wood or high-strength composite panels.
Each arc is calibrated and polished to the millimetre level to ensure that the final structure perfectly matches
the designed curve, laying a solid foundation for subsequent frame assembly and fabric covering.

The production of the curved section is particularly critical, typically employing either steam bending or
segmented splicing. For steam bending, workers place the dried wood in a high-temperature steam box to
soften the internal fibres. The wood is then quickly placed into a specialised curved mould and securely secured
with specialised clamps. Once the wood has completely cooled and dried, a stable curvature is achieved.
For segmented splicing, the wood is cut into precisely angled segments, assembled one by one using
high-strength wood glue and invisible mortising. Then, clamps are used for a long period of pressing to ensure
secure joints and a natural curve. Regardless of the process, meticulous polishing ensures a smooth, burr-free
surface for the curved frame, providing an ideal foundation for subsequent cladding.

The neatly stacked, cut and polished layers of solid wood create a clear, sturdy wooden frame, laying a solid
foundation for subsequent filling and covering. This process not only ensures the sofa’s overall load-bearing
capacity and stability, effectively extending its lifespan, but also provides a smooth, even exterior for the
finished product, ensuring the sofa meets high standards in both comfort and aesthetics.

The main frame is constructed from rigorously screened, high-strength solid wood or high-quality multi-layer
boards, ensuring they are crack-free, insect-free, and have a controlled moisture content to prevent deformation
or cracking. Precision saws are used to cut the wood with precision, ensuring that the angles and lengths of
each component meet millimetre tolerances as specified in the design drawings.

Following cutting, the wood’s surface and edges are meticulously polished using a belt sander and
hand-sandpaper to remove burrs and sharp angles while ensuring a smooth surface, laying a solid foundation
for subsequent structural assembly and cladding.

High-density, high-resilience high-quality sponge is selected as the filling material to ensure good support
and shape stability after long-term use. According to the designed arc contour, the sponge is placed on a
large CNC cutting machine for precise cutting. Each piece strictly matches the curve of the frame to ensure
the fit of the subsequent covering.

The seat part adopts a multi-layer superimposed structure: the bottom layer is a supporting sponge with
higher hardness to provide solid support; the middle layer is a cushioning sponge with moderate elasticity
to enhance sitting comfort; the top layer is covered with soft and delicate high-elastic foam for a gentle touch.

A slightly lower density sponge is used for the backrest to better fit the curve of the human body and reduce
back pressure. All sponges will be chamfered after cutting to make the edge transition rounded, which not only
facilitates the smooth covering of the fabric, but also makes the lines of the finished product fuller and smoother.

Corners and curved areas require manual trimming of the sponge’s edges to perfectly match the curves of
the frame. Once all the adhesive is attached, workers check the sponge’s stability and flatness by pressing
and tapping it to ensure a full, smooth appearance when subsequently wrapped with fabric.

The cut fabric is evenly stretched and wrapped around the sponge and frame outer layer according to the
pre-marked positioning points and stitching directions. Workers will adjust the tension according to the stress
conditions of different parts, using a wrapping process with moderate tension and segmented fixing to ensure
a firm fit while preventing wrinkles or sagging in the fabric.

For curved corners, a multi-segment splicing and gradual stretching method is used to adjust the fabric little
by little to the optimal position, ensuring that the curve of the corner is natural and smooth without being
pulled or deformed. After the wrapping is completed, the seam position will be reviewed and slightly reshaped
to ensure that the overall appearance is full and rounded, and the lines are smoothly connected, highlighting
the sophistication and high-end feel of the sofa.

A soft, delicate suede fabric with a smooth touch is selected as the outer covering material. Before entering
the production process, it undergoes an anti-fading treatment to ensure that the color remains rich after
long-term use, an anti-static treatment to prevent dust adhesion, and an anti-pilling treatment to maintain
a smooth and clean surface.

When cutting, the sofa is cut into blocks according to the curved modular structure, and the layout is strictly
unified according to the natural direction of the velvet to prevent color differences or inconsistent reflections
in the finished product. Each piece is precisely spliced by experienced sewing workers operating industrial
sewing machines, with even stitches and consistent stitch lengths. The seams are reinforced to not only
enhance strength but also keep the lines straight during subsequent stretching and wrapping, ultimately
presenting an appearance that is both durable and refined and smooth.

The sturdy, round plastic feet provide a secure support for the sofa and protect the floor from scratches.
On the right side is a polished, exquisitely crafted metal lock mechanism that secures the fabric underneath
and facilitates future removal or maintenance. This thoughtful design not only enhances the sofa’s durability
but also facilitates daily cleaning and maintenance.

After assembly, workers use a special suede brush to smooth the fabric texture, ensuring a smooth touch
and uniform color. Quality inspectors perform stability tests, fabric flatness checks, seam tightness checks,
and appearance checks to ensure every sofa leaves the factory flawless.

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