We’ve all been there. You sit down on a cheap sofa, and it feels like sitting on a pile of damp cardboard. It’s hard, uncomfortable, and just not what you need to relax after a long day of work. Then, you sit on a proper, high-quality sofa, one that supports your spine and has comfortable cushions in all the right places. It feels like a warm embrace that you come home to at the end of the day.
But have you ever stopped to wonder how sofas are made? Especially those super-comfortable, high-quality, durable sofas. What goes into making them? What materials are used to make them? How long does it take to actually make a made-to-order sofa? All very good questions.
From the first sketch to the final stitch, there’s a lot of love and attention that goes into every piece. In this guide, we’re pulling back the curtain to show you exactly how high-quality sofas are made, from the materials used to the time that it takes.
What are sofas made of?
Before we talk about how they are made, let's talk about what they are made out of. Just as with anything made, a high-quality sofa is only as good as its ingredients. If you start with cheap wood and flimsy foam, you’re going to end up with a sofa that sags a lot faster than you would expect. So what are good materials, you ask? Let’s break down the different layers of a sofa and the materials manufacturers should use for each.
The frame
The frame is the most important part of the sofa. It’s the skeleton that makes up the whole thing. It takes all the weight, the movement, and the occasional jump from a hyperactive toddler. Without a strong frame, your sofa is already set up for failure.
We live in a world where mass-produced sofas are becoming more common. Most of these sofas are built for speed and low cost. They often use particleboard, MDF (Medium-Density Fibreboard), or thick cardboard, all held together with staples and weak glues or adhesives. Over time, these materials crumble or pull apart, leading to a wobbly and unstable sofa.
On the other hand, high-quality sofas are made from hardwoods like oak, birch, or beech. Wood naturally contains moisture, so this must be accounted for when making sofas. If you build a sofa with green wood (unseasoned, high-moisture timber), it will eventually dry out, causing the frame to warp, shrink, and crack. Drying the wood in a kiln first ensures the frame remains rock-solid for a long time.
While high-quality wood is important, how it is joined is equally important. Most high-end manufacturers use double-doweled joints reinforced with corner blocks. This means the corners are physically locked together with wooden pegs and screws, rather than just relying on a prayer and some PVA glue.
The suspension
This is what gives the sofa its signature bounce. Without good suspension, even the best cushions will eventually feel flat. Let's start off with what springs are used in high-quality sofas.
First up are serpentine or zig-zag springs. These are the most common high-quality options. They are S-shaped steel wires that run across the frame. They provide a firm but flexible support base. In a premium build, these are spaced closely together to prevent gapping between the springs, which would cause holes in your sofa that you might sink into from time to time.
Next, we have eight-way hand-tied springs, quite the mouthful. These springs are often considered the pinnacle of sofa construction. Manufacturers manually tie individual coil springs to one another and to the frame using high-strength twine in eight directions (side-to-side, front-to-back, and diagonally). This helps the sofa support you evenly, no matter where you sit.
In some modern or low-profile designs, high-tension elastic webbing is used. While cheaper versions can stretch out, professional-grade Pirelli webbing provides a supportive feel that’s perfect for modern styles.
The fabrics
Whether you’re a velvet lover or a linen enthusiast, the fabric you choose needs to be durable enough to stand the test of time. How do we test which fabrics are best for top-notch sofas? Well, let's talk about the Martindale test. This test simulates natural wear and tear by rubbing a piece of wool against the fabric until it breaks. This gives you a metric called the “rub count”. For a domestic sofa, you want a rub count of at least 20,000. For a busy home with kids and pets, we aim for 40,000 or higher.
Natural fibres like cotton and linen breathe beautifully and feel luxurious, but they can be prone to wrinkling. Synthetic blends (such as polyester or acrylic) provide durability and stain resistance. So, for sofas that are likely to get more use, consider synthetic fabrics; if you have a sofa that is more of a showpiece, go for natural fabrics.
If you’re in the mood for leather, you want to make sure you get a sofa made of top-grain or full-grain leather. Unlike bonded leather (which is essentially leather scraps glued together), real hide develops a “patina” over time. A patina is a thin layer that develops on a leather surface over time. It adds a sheen and darkening to the surface of the leather, which adds a bit of character to the sofa.
How are sofas made? How these materials come together
So, how does a pile of timber and a roll of fabric become the centrepiece of your home? Let's walk through the in-depth process of building high-quality sofas. We will go over the specific process we use at Heatons Furniture to make a made-to-order sofa, from design through final delivery.
Step 1: The design and planning stage
Every great sofa starts on a drawing board. When it comes to designing a sofa, it’s important not just to think about looks but also to think about physics. Here are some of the design elements that we keep in mind when the sofa is still on the drawing board:
- Ergonomics: We calculate the backrest angle that prevents you from feeling you're leaning too far back or being pushed forward.
- The depth: Do you want to sit on the sofa or “in” the sofa? Planning the seat's depth and height determines whether the sofa is more supportive or a proper lounger.
- Bespoke adjustments: Because it's made to order, this is where we can adjust arm widths or leg heights to suit your specific room layout.
Step 2: Building the frame
Once the blueprints are finalised, we can get started on the woodwork. Any high-quality sofa requires precision cutting for a more polished look. Using a mix of machines for accuracy and hand-finishing for detail, the hardwood is cut into the numerous different shapes required for the arms and rails.
We then make sure that the frame and all the stress points are reinforced. If a sofa is going to fail, it usually fails at the joints. By adding extra reinforcements, such as stiffening rails, we ensure the frame can handle the weight of your partner, your kids, and even your family's Golden Retriever without breaking a sweat.
Step 3: Installing the suspension and webbing
This is where the "ride" of the sofa is determined. The ride is the sofa's supportive feel, comfort level, and stability. It comes down to how the springs, cushioning and frame all interact with each other. The springs are fixed to the frame using lined clips (to prevent squeaking)
We ensure that every spring is at the exact same height. If one is slightly higher, you’ll feel a lump in the seat. It takes a keen eye and years of experience to get this level of consistency. That's where all of our experience at Heatons Furniture comes in handy.
Step 4: Padding, foams, and upholstery
This is the stage where the skeleton that was built gets the comfy cushioning that makes a sofa, well, a sofa! We don't just use one block of foam. We use a few layers, with a firm core for support, wrapped in a softer outer layer for that cloud-like feeling.
The Tailoring is probably the most labour-intensive part. The fabric is hand-cut using patterns. If the fabric has a pattern (like stripes or florals), we have to ensure the pattern flows seamlessly from the back cushion down to the seat and over the arms.
Once the fabric is secured, we can move on to the buttoning and detailing. Whether it’s deep-buttoning (like a classic Chesterfield) or sleek top-stitching, these final touches are all done by hand with a long needle and a lot of patience.
Why choose a made-to-order sofa?
You might be wondering, "Why wait for a sofa when I can go to a sofa chain store and get one today?" The truth is, made-to-order furniture is an investment in your future comfort and the environment.
Firstly, made-to-order sofas are always going to be the perfect fit for your space. We’ve all seen a sofa that looks great in a massive showroom but looks like an elephant in a small apartment. By choosing made-to-order, you can customise dimensions to ensure the proportions are exactly right for your home.
It will also suit the style and mood of your space much better. Most retailers offer 3 or 4 colours. With made-to-order, you have the choice ofhundreds. This means your sofa can be a true reflection of your personality, whether that’s a vibrant burnt orange velvet or a sophisticated herringbone wool.
Finally, mass-produced furniture is often disposable. It’s designed to last 3–5 years before it ends up in a landfill. A high-quality, handmade sofa is designed to last 15–20 years or more. You can even have it reupholstered in a decade to give it a second life.
When you buy bespoke, you’re often supporting local workshops and skilled artisans who have spent decades perfecting their trade.
How long does it take to make a sofa?
We get this question a lot. In a world of next-day delivery, waiting a few weeks can feel like an eternity. But you have to keep in mind that due to the quality of the made-to-order sofas we make, it does take a bit of time to get them made. While the option for a mass-produced sofa is always there, they are going to lack in quality and durability.
A handcrafted, made-to-order sofa usually takes anywhere from 6 to 12 weeks. This timeline accounts for:
- Procurement: Sourcing the specific fabric you chose from the mill.
- The queue: Your sofa is built one at a time, not on a conveyor belt.
- The curing: Glues and finishes need time to set and "off-gas" properly before being wrapped for shipping.
- Inspection: Every inch is checked for loose threads, uneven tension, or frame imperfections before it leaves the workshop.
Getting a made-to-order sofa with Heatons Furniture Outlet
Understanding how sofas are made gives you a new appreciation for the furniture in your home. It’s more than just a place to watch Netflix! Your sofa is an investment in your long-term happiness and comfort.
When you choose made-to-order furniture, you’re supporting craftsmen who care about quality. You’re choosing materials that won't end up in a landfill in three years. Most importantly, you’re choosing the best possible seat for your Sunday afternoon naps.
Ready to find your forever sofa? Browse our made-to-order collection and give us a call or visit us in store, and let’s start building something beautiful together.
