Building a sustainable BIOSOFA - making ecofriendly furniture step by step - part 6/6

by tine sintermann on January 07, 2021

D3CO makes sustainable furniture 100% natural ecofriendly

Part 6: Backrest and cushions

Seeing a piece of furniture come to life is a wonderful moment each time. We know that the piece of furniture will live in your home and will accompany you for a long time. I will be of highest quality and also feature only natural materials, no plastic, no toxins, no harmful materials or chemicals. We pride ourselves in carefully selecting materials only from trustworthy sources and being able to build an eco-sustainable piece of furniture that will bring joy to any customer and their home.

Cushions for final sofa


Final steps - a cushion’s weight makes the difference

Generally, a backrest is softer than the seat cushion of the sofa. Therefore, we need to produce them in different ways. The backrest will be made from pure feathers and is actually a cushion within a cushion. The technique we use to keep all this soft material in place is to sew it into air compartments, sort of like you would do with a down jacket. We’re able to calculate the size of these chambers by once more consulting our 3D computer model.

We’re now pumping feathers into the cushion while constantly checking on its weight. By the weight, we can control that the outcome is the same every time. We continue to sew a covering for the inner cushion which also features our dedicated chambers. Comfort is so essential for any sofa and other pieces of furniture, and these steps are carefully executed because the human back needs the maximum comfort.

The cushion is now surrounded by the final textile cover, which is again cut on our automated cutting table. As with the sofa textiles, the cushion covers can also be removed, cleaned or repaired easily at all times.

Ecofriendly sofa Casquet: sustainable materials and building methods


Please take a seat!

For the seating cushion we need material that can sustain more weight and will bounce more dynamically than a feather cushion will be able to. The inner layer for the seating cushion will be a latex layer featuring 10 to 20 centimeters of thickness. Once again, using our 100% natural latex! These latex pieces will finally be covered by a feather chamber cushion, much like the outer ones on the backrest.

Again, we check with the 3D model to give us the exact measurements for the final textiles, which we will cut and sew. Performing the last steps is assembling the feet and executing our quality control routine, double-checking all measurements and features.

We test it for comfort, document the piece, put a piece of the original cover textile in an envelope for you, so that you always have a colour reference, and start smiling: the sustainable sofa is now ready to ship out and make the customer smile in turn.

Finally, the textile you chose as your top cover is coming into play. To avoid shrinking due to cleaning, we pre-wash it for you, then cut and sew it to perfectly match your furniture. Removing your textile cover is quite easy and done by opening our steel and cotton zippers and / or removing small metal clips or wooden fastenings on the bottom of the sofa. Even though our materials are proven and robust, you might want to clean it from time to time or repair it when damage happens. We ourselves have many kids in our Italian families, and we know how quickly a gelato can drip onto a cushion by accident. In any case you won’t have to throw the cover or the furniture away!

Finalizing Casquet, Details, Cushions and armrests 

Casquet natural sofa with wings - final product



Sustainable furnitureSustainable Sofa Ecofriendly Sofa MakingPart 4 of making sustainable furnitureEcofriendly furniture from D3CO in MilanPart 6: Finalizing our sustainable and ecofriendly sofa Casquet at D3CO Workshop Milan