How is Upholstered Furniture Made?

Frame

Upholstered furniture starts with a wood frame. Manufacturers may use locally and sustainably sourced hardwoods or cheap particleboard, pressed wood, or MDF frames. If pressed or composite woods are used, they are likely bound with toxic resins.

Exposed wood legs are often treated with stains, varnishes or sealers that may be toxic.

Springs

Attached to the frame are sinuous metal (aka serpentine) springs or coiled springs that may be hand-tied with twine for stability and durability, or a combination of both. Sinuous metal springs are more common and less expensive, and may be just as durable provided the gauge of the wire is sufficient. Many manufacturers, including Ethan Allen, are using metal springs with recycled metal content.

Foams & Fiber

High density foam is the next layer, which is then often wrapped in polyester fiber or down feathers. Sometimes a memory foam or lighter weight foam is used together with the denser material, and the layers will be glued together with spray adhesive which may be toxic. 

Natural latex foams are a non-toxic alternative to polyurethane foams. Wool and natural cotton is often used in place of the polyester fiber wrap. Companies like Adaptive Fiber are innovating with recycled plastic bottles for fiber materials. 

Adhesives

Adhesives are used to bind foam layers and also often to bind foam to the frame. Traditionally, highly toxic spray adhesives are used. Simalfa water-based adhesive is the greenest option that is also effective, according to manufacturers like Pure Upholstery. 

Fabric or Leather cover

The upholstered piece is then ready to receive the final upholstery fabric or leather, which may be treated with toxic stains and water repellents. The chemicals used in tanning leather are often highly toxic. Many non-toxic alternatives exist on the market, including choosing organic natural fabrics over synthetics, vegetable-tanned leathers, or leathers made from vegetable fiber.

Barrier cloth

Foams and cushions are covered in a barrier cloth which further protects and makes the underlying materials more durable. The least toxic option is organic cotton canvas instead of polyester.