Eight steps, all under one roof

A curved sofa is not a straight sofa bent afterwards. The frame parts are cut to a set of parameters, so every piece in a batch matches and the left side mirrors the right.

Fabric goes on last. It covers the curve, it does not make it. The same drawing can look soft in one workshop and flat in another, and the difference sits in the steps below.

All eight run in our own workshop in Longjiang, Foshan. Where a step is missing, it is outsourced. Worth asking about when you visit a factory.

Production Process

01 CNC Cutting

Frame parts cut from the same parameters. Left and right sides mirror.

02 Frame Assembly

Segments joined with dowels or blocks and adhesive. Not screws alone.

03 Sponge Cutting

Foam cut along the curve. Square foam leaves hollow spots.

04 Backing Padding

Backrest padding shaped to the back curve.

05 Fabric Cutting

Patterns drawn per model. Straight-sofa patterns do not fit.

06 Fabric Fabrication

Panels sewn with seams kept away from the visual focus.

07 Upholstery Assembly

Tension set by hand. Loose wrinkles; tight distorts the curve.

08 Quality Inspection

Size, appearance and structure checked before packing.

Machines behind the steps

CNC Cutting Machine

Cut from digital files, so the same shape repeats piece to piece.

Computerized Fabric Cutting

Panels laid out by machine, grain and pattern kept aligned.

DURKOPP Sewing

German machines: even stitch length, straight lines.

CAD Pattern Design

Every model drawn and stored before cutting.

What you can change

Two ways to start: drawing-based customization, where we build to your drawings, or sample-based customization, where we take an existing model and adjust it.

Dimensions

Length, depth and seat height adjusted per configuration.

Configuration

Seat count, chaise and ottoman. Straight, curved, modular and special shapes.

Upholstery

Fabric, leather, tech fabric or cut velvet. Colour from the current range.

Curvature

New radius means new patterns and panels. Treated as a new model, not a size tweak.

Materials and build

Standard construction is a Russian pine solid wood and plywood frame with high-density foam, covered in the fabric or leather you pick. Corners are reinforced, and foam density is agreed before production rather than discovered at the sample stage.

Upholstery comes from the swatch library below. If a colour is not on the rack, we can work to a supplied sample.

Fabric and leather swatch library used for upholstery selection

What we check before packing

Symmetry: from above, both curves mirror.
Seams: kept away from where the eye lands.
Corners: pleats even, no bunched fabric.

Hollow spots: press the middle of the curve, it should not sink.
Pile direction: velvet and directional fabric all run one way.
Seat rebound: compresses evenly and comes back.
Incoming materials: identified and traced back to the batch.
Finished product: full inspection before packing, not spot checks.

Capacity

200,000+

pieces a year

15,000+

pieces a month

500+

pieces a day

Sofas, upholstered beds and whole-house furniture run on separate lines. OEM and ODM orders have their own lines, so a custom run does not queue behind stock orders. Splitting small and large volumes cuts delivery time by about 30%.

Sampling and delivery

ODM projects: 7 days for a sample, 15 days for delivery. Volume orders and new curvatures are scheduled by model, quantity and fabric, and confirmed in writing before production starts.

Export orders come with target-market compliance documents and customs clearance papers at no charge.

Send a drawing or a reference photo

Tell us the size you need. We reply within 24 hours with the closest existing model, or a quotation for a new pattern.

Request a Quote

Or call +86 139 2877 9149.

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