Building a sustainable BIOSOFA - making ecofriendly furniture step by step - part 3/6

In our previous articles we explained how we take an idea to a sketch and then turn it into a complete 3D model and eventually create the wooden skeleton for the sofa Casquet - which we are using to showcase how we make an eco-sustainable, plastic-free biosofa here at D3CO. If you’ve missed our two previous parts of our ‘Making Of’ episodes, check them out here.

Comfort starts early

After the wooden frame is set up, we’re installing the base on which all cushioning will be placed. We call it the elastic layer and it’s an incredibly important part to ensure the final piece will be flexible and comfortable. The way we make sure that the product base will be not only comfortable, but also long-lasting and robust is by installing vertical and horizontal stripes of jute right under the frame. The woven jute pattern is fixed with steel nails. Steel springs are clamped together with large steel staples.

Layers of material

An extra layer of criss-cross belts is applied to the top and inner backrest and fixed to the steel springs. When everything is fastened, an extra piece of pure jute cloth is cut and added to cover the entire web of belts and springs. We like to do this to so that the next layers of textile and cushioning feel really smooth.

Preparing for the next stages

We now have a wooden frame with a first elastic layer made out of jute and steel springs. The next step in making an eco-sustainable piece of furniture is the latex and felt layer to provide additional comfort.