Thursday, February 15, 2018

Slim, Sculpted Floor Seating

We were recently presented with some very pretty round covers with a knife edge (knife edge is two pieces of fabric sewn together, like a bed pillow) and asked to make very firm inserts so that the client could use them as floor cushions.  Unlike a sofa cushion which has a boxing panel sewn in which allows for the blockiness of a foam core, a knife edge seam doesn't fit a foam insert.  Our solution was to shave down the edge of the foam to make it sharp which will neatly fit with the cover's seam.  We then wrapped the foam with polyester which softens further the shape of the foam and takes the slack out of the fabric, tightening it and removing wrinkles.  Once the inserts are installed in the covers, a full, firm insert is ready for the home.

Thursday, November 30, 2017

Die Cut Foam

We just provided a client with 7,000 pieces of die cut foam to be used in packaging their liquid filled flasks for shipping.  They needed a charcoal gray foam that would have 12 round holes that went all the way through the foam.  We had a sample made for approval, made a slight adjustment on the diameter of the hole and put the job into production.  The pieces were delivered and the product was received in time for Holiday shipping.

A phone call leads to a sketch.  Close but not quite right.

A 3-D illustration helps everyone to visualize the end product. 

We cut one sample for approval.  The diameter of the holes was a little too small.
The final product held the snugly fit the flasks.

Wednesday, September 20, 2017

Fun with Foam Shapes

We recently cut this set of foam triangles.  Don't know how they are being used, but we like to line them up on the table in an obvious formation.

Friday, February 5, 2016

Magazines We Like!

Flipping through the terrific book and periodical selection at the Museum of Craft & Design in San Francisco we found Dirty Furniture, it's debut issue is right up our alley because it is all about sofas!  Articles cover such diverse and wonderful subjects as odd objects found in sofas, how foam is made, a great photo essay on artist's sofa designs and Freud's sofa.

In our shop we have the perfect pile of old cushion foam on which to display our prize copy of Dirty Furniture.

As long as we are recommending favorite publications, we also cannot get enough of Apartamento.  What's in it you ask?  What ISN'T in it we reply.  Anything goes in this magazine, from Picasso and Gary Panter's home studios (no, they didn't live together) to a gorgeous painted essay by Jean-Phillipe Delhomme.  We like it that the editorial approach isn't about perfect spaces that are designed for the photographic team that arrived the day after everything was installed, but rather these are real lived in spaces that are reflective of the personalities of the owners and are often, thankfully, a bit messy.

Upholsterer Don Miller enjoys the latest issue of Apartamento.

Thursday, June 25, 2015

Back Cushion Rejuvenation

Most furniture ships with back cushions filled with either polyester or a down/feather blend and sometimes with down/feather blended with polyester.  With normal use the polyester filled inserts will start to show wear and begin to sag.

We were recently brought some sagging fiber/down filled backs.  Fiber/down is the filling that blends down/feather with polyester.  Although down/feather on it's own is fluffable, once it's blended with polyester it gets tangled in the poly fibers and as the batting wads up and flattens, so too does the down/feather.  These cushions had lost their fullness, were drooping severely and provided no support (the picture below says it all) for their owners.

We emptied the backs of the fiber/down filling, as you can see it comes out in ropey bands of wadded up polyester and feathers.

After emptying the tick, we refilled it with Cluster Fiber, making the insert very firm, supportive and full.

Lots of Cluster Fiber filled into the existing tick makes the insert much fuller and firmer than before.

The new cushion is dramatically fuller than the old cushion.

By the way, we never mix down/feather with polyester.  Either we make a polyester filled cushion which is firm, or a down/feather cushion which is fluffable, or a foam core poly