What happens between layout approval and the first cut?
Knowing how Arabic sofas are made at the atelier explains several things a buyer notices later, such as why a long wall is covered by more than one seat and why the cushions arrive flat.
Custom orders start with a layout plan for your approval.
Once the plan is signed off, the fabric for the order is brought into our Istanbul workshop, and cutting starts from the measurements on the drawing.
Step 1: how is the foam cut for each seat?
A floor sofa or full-foam majlis seat has nothing hard inside: no wooden or metal frame and no springs, only foam that holds the shape on its own. Seat foam ranges from medium-firm to firm, and you can ask for a softer or firmer fill before production starts.
| Part | Built from | What you choose |
|---|---|---|
| Seat cushion | High-density polyurethane foam | A thickness of 4 in (10 cm), 8 in (20 cm), 12 in (30 cm) or 16 in (40 cm) |
| Backrest | A separate foam piece, not sewn to the seat | Shape and fabric to match the seat |
| Wooden-frame base and back | Solid pine or MDF, with carved back panels in MDF | Optional, since most designs can also be made as all-foam seating |
| Cover | Upholstery fabric closed with a zipper | Velvet, chenille, linen-look or cotton-polyester blend, or a heavy kilim-style weave on the Sedir Bench line |
Seats use high-density polyurethane foam — ask us for the exact density for your build. The guide to sponge and foam quality goes further into density and firmness.
Step 2: how are the covers cut and sewn?
The upholsterer cuts the cover fabric around each foam piece and sews it into a fitted cover with a zipper, so the cover can come off later without unpicking a seam.
A single seat piece stops at about 75 in (190 cm), which means a long wall is shared between two or more cushions of the same length. Shorter pieces keep a pattern lined up from one cushion to the next, and they can be pressed for shipping.
Covers unzip and can be machine-washed on a gentle 86°F (30°C) cycle. Keep them out of a hot dryer, since heat can shrink the fabric.
Step 3: why is the set laid out and photographed before packing?
This is the step where the workshop sets a custom order out on the floor in the shape of your room and gives every piece a number, so the same order can be followed at home.
Custom orders are photographed and filmed for your approval before they ship.
Step 4: why does foam travel vacuum-packed?
Each foam piece goes through a press, is rolled and sealed in a vacuum bag, and only then goes into a box. Once the bag is opened, the foam swells back to full size and cannot be pressed flat again at home, which is why the boxes are small for the size of the set.
Plan to open the bags within roughly a week of the boxes arriving, then leave the cushions for about a day so they can return to their full shape before anyone sits on them.
Where does the upholsterer's trade come from?
The trade has changed its materials far more than its basic job of shaping padding and fitting cloth over it.
| Point in the history of the trade | Source |
|---|---|
| The word is usually traced to the Middle English 'upholder', an artisan who made fabric furnishings | Encyclopedia entry on upholstery |
| In 18th-century London, upholsterers were organized in the Worshipful Company of Upholders | Encyclopedia entry on upholstery |
| Modern upholstery typically uses polyurethane foam, lighter than the animal hair and coir once built up layer by layer | Encyclopedia entry on upholstery |
| Elias Howe Jr. received US Patent 4,750 on 10 September 1846 for a sewing machine with an improved lockstitch | Library of Congress business history guide |
Frequently asked questions
Are your floor sofa sets handmade, and how can I judge the quality before ordering?
Each set is made at our Istanbul workshop, where the foam is cut to size and our upholsterers sew a cover for every piece. Seats use high-density polyurethane foam — ask us for the exact density for your build. To judge the quality yourself, ask for photos and videos of finished orders. Ask us about fabric swatches and a foam sample before you order.
Is there a frame inside a majlis seat?
Not in floor sofas or full-foam majlis, which have no wood or metal frame and no springs inside. A custom majlis can instead sit on a wooden base and back, with foam seats on top, and most designs can be made either way.
What wood is used in the wooden-frame models?
The base and back of a wooden-frame model are made of solid pine or MDF, and carved back panels are always MDF. The Sedir Bench line uses a solid pine frame under foam seats, upholstered in a thick kilim-style weave.