The Art of Building Your Biosofa
Conceptualization and Prototyping: Crafting Biosofa's Vision
Witness the designers of ddp studio presenting the first model of Casquet. What comes next is the 3D model creation for the Casquet sofa.
Our product developers will start to optimize and refine the 3D model, calculating textile sizes and cutting patterns for production.
Furniture making is a collaborative process. Only when everybody involved in the development of the new sustainable sofa gives a green light, the proper production can start.
Witness the designers of ddp studio presenting the first model of Casquet. What comes next is the 3D model creation for the Casquet sofa.
Our product developers will start to optimize and refine the 3D model, calculating textile sizes and cutting patterns for production.
Furniture making is a collaborative process. Only when everybody involved in the development of the new sustainable sofa gives a green light, the proper production can start.
Artisanal Woodwork: Crafting the Backbone
Biosofa products never include chipboard or MDF, and our specialized team preserves the woodworking tradition of our region, Brianza.
We have a true hands-on approach as wooden pieces are cut, sanded, measured, and assembled under the skilled guidance of head carpenter Fabio Solenne.
We now complete the wooden under-frame, the backbone ensuring Biosofa's longevity and stability.
Biosofa products never include chipboard or MDF, and our specialized team preserves the woodworking tradition of our region, Brianza.
We have a true hands-on approach as wooden pieces are cut, sanded, measured, and assembled under the skilled guidance of head carpenter Fabio Solenne.
We now complete the wooden under-frame, the backbone ensuring Biosofa's longevity and stability.
Foundation of Comfort: Jute and Metal Springs
Understand the significance of the elastic layer, incorporating vertical and horizontal stripes of jute to enhance flexibility and comfort.
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.
Now comes the finishing of the woven jute pattern fixed with steel nails and the application of criss-cross belts for added support.
Witness the final touch as a pure jute cloth covers the entire web of belts and springs, ensuring a smooth foundation for the next layers.
Understand the significance of the elastic layer, incorporating vertical and horizontal stripes of jute to enhance flexibility and comfort.
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.
Now comes the finishing of the woven jute pattern fixed with steel nails and the application of criss-cross belts for added support.
Witness the final touch as a pure jute cloth covers the entire web of belts and springs, ensuring a smooth foundation for the next layers.
Natural Layers: Cotton Felt and Latex Padding
Experience the art of cutting down large blocks of natural latex to create various softness levels, shaping the sofa as envisioned in the initial sketches.
Latex is delivered in large blocks and we cut it down to the needed sizes in the correct height and length using our large scale vertical saw.
This process takes experience and craftsmanship, as the material is very soft and any push or pull in the wrong direction will result in an uneven cut.
The layering process allows our artisans to sculpt the sofa, especially when crafting designs with rounded or soft lines.
By carefully applying the different layers of latex we can sculpt the sofa as envisioned in the first sketches. This really is the difficult part, and here all the workmanship of our artisans really plays out.
To protect the latex cells from dust and damage, we apply an extra protective layer of recycled cotton felt. This layer will also provide a firmer feel and keep the relatively wobbly latex foam compact and in shape.
Understand the role of the cotton layer in supporting the final textile cover, ensuring a seamless finish without creases or folds.
Experience the art of cutting down large blocks of natural latex to create various softness levels, shaping the sofa as envisioned in the initial sketches.
Latex is delivered in large blocks and we cut it down to the needed sizes in the correct height and length using our large scale vertical saw.
This process takes experience and craftsmanship, as the material is very soft and any push or pull in the wrong direction will result in an uneven cut.
The layering process allows our artisans to sculpt the sofa, especially when crafting designs with rounded or soft lines.
By carefully applying the different layers of latex we can sculpt the sofa as envisioned in the first sketches. This really is the difficult part, and here all the workmanship of our artisans really plays out.
To protect the latex cells from dust and damage, we apply an extra protective layer of recycled cotton felt. This layer will also provide a firmer feel and keep the relatively wobbly latex foam compact and in shape.
Understand the role of the cotton layer in supporting the final textile cover, ensuring a seamless finish without creases or folds.
Tailoring Textiles: Inner and Outer Covers
The addition of a white cotton undercover will support the final textile cover to run smoothly and prevent creases or folds.
Each textile has its own little features and challenges. With velvet for example, the lay of the soft surface will reflect the light differently depending on the direction of the weave.
With the 3D model that we have created early in the process, we’re now able to get the exact cuts for the textiles. We pass the shapes into our dedicated cutting program which is linked to our automated large scale cutting table. With its size of 3 x 8 meters and a movable arm we’re able to easily and precisely cut all the material.
Once all textile pieces are cut, our seamstresses clean them and assemble the covers while borders, zippers and threads are matched to the textile color.
Sewing a sofa is hard work. All parts are heavy, and need to be assembled exactly. Often, the final stitching is very visible and must be absolutely perfect to pass quality control.
Zippers, buttons, closures and decorative seams are the last steps in the Biosofa sewing process.
The addition of a white cotton undercover will support the final textile cover to run smoothly and prevent creases or folds.
Each textile has its own little features and challenges. With velvet for example, the lay of the soft surface will reflect the light differently depending on the direction of the weave.
With the 3D model that we have created early in the process, we’re now able to get the exact cuts for the textiles. We pass the shapes into our dedicated cutting program which is linked to our automated large scale cutting table. With its size of 3 x 8 meters and a movable arm we’re able to easily and precisely cut all the material.
Once all textile pieces are cut, our seamstresses clean them and assemble the covers while borders, zippers and threads are matched to the textile color.
Sewing a sofa is hard work. All parts are heavy, and need to be assembled exactly. Often, the final stitching is very visible and must be absolutely perfect to pass quality control.
Zippers, buttons, closures and decorative seams are the last steps in the Biosofa sewing process.
Comfort in Detail: Backrests and Cushions
The backrest will be made from pure feathers (or a vegan alternative) 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.
The inner layer for the seating cushion will be a latex layer featuring 10 to 20 centimetres 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.
The backrest will be made from pure feathers (or a vegan alternative) 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.
The inner layer for the seating cushion will be a latex layer featuring 10 to 20 centimetres 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.
Precision Perfection: Quality Control
We double-check 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.
Your Biosofa is now a masterpiece, ready to be shipped and bring joy to your home.
We double-check 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.
Your Biosofa is now a masterpiece, ready to be shipped and bring joy to your home.