How is Upholstered Furniture Made?

We're proudly made in North Carolina by the best artisans in the business! Learn how our furniture is made and get inspired to design your own!

ORDER IS RECEIVED

1. Your order is entered into a Materials Requirement System, which notifies Manufacturing of the materials needed for the order.

2. Once scheduled for production, our CAD system sends files to the Frame, Cushion, and Poly Departments to create the parts needed for manufacturing.

3. While the frame is being cut and assembled, the cushions and poly are being prepared to Coley Home specifications. The fabric is also being pulled from inventory to begin the cutting process.

CUT & SEW

4. Fabric is measured for width and vertical/horizontal repeats, and this information is entered into our CAD system, which contains all pattern parts. All pattern parts are lined to Coley Home specifications

5. The fabric is placed on our CAM system, and the operator pulls the corresponding CAD file for the order. The order is then cut, and each piece is inspected. For more complex orders or those with multiple fabrics, paper patterns are also used. This requires a highly skilled cutter to manually lay out the pattern parts and cut them to specification.

6. Once cut, the order is sent to the Sewing Department. Each style has specific specifications detailing how each part of the furniture is sewn together. All parts for the body of the piece are sewn first, followed by the backs and cushions.

7. Once the parts are sewn together, French seams are added as specified for a more refined look. A serger is also used to finish the raw edges of the seams. The order is now ready for upholstery.

FRAME & SPRING UP

8. Frame parts for the order are pulled and assembled to specifications using glue and large industrial staples.

9. Once the frame is assembled, sinuous springs are added to the seats and backs as required. Nylon webbing is also applied to the open areas of the frame for added support.

10. All parts are now ready, and the cushions and poly have been delivered by the vendor. All parts are now delivered to one of our skilled craftsmen to be built.

UPHOLSTERY 

11. The Insider will add poly, fiber, and cotton to the arms, seats, inside backs, and outside arms. The fabric is then stretched and adjusted for a clean fit, and secured with staples. Once complete, the Insider will send the piece to the Trimmer.

12. The Trimmer will do any detail work, such as adding welts, and apply seamless parts - such as an outside back. Any legs or swivels will also be applied here. The cushion and backs are then filled to specification. 

INSPECTION & PACKING

13. We now have a completed piece. The order is inspected and compared to the customer’s original specifications. Once it passes inspection, the piece is cleaned, refreshed, and sent to packing.

14. Packing has specifications for how each piece packs. The piece is placed in a heavy-duty cardboard tray and a soft nylon bag is draped over it for protection. A plastic shrink bag is placed over everything and heated to secure it in place. Foam blocks are added to any areas that need extra protection.

15. Once packed, a cardboard box fitting over furniture is applied for an added layer of protection

16. The order is now ready to ship!