Our primary vendor operates from a 100,000 sf factory in central florida. Here's a quick tour of
the factory, so you can see how your order is made.
Most orders start out in the cutting room. Here around 500 fabrics are available, including all of
the Sunbrella range. The cutters prepare the fabrics for sewing, by cutting individual orders by hand. It's worth
mentioning that this video was shot in September, which is traditionally a slow time for this industry. In the
season's peak, this factory employs nearly 100 people.
From cutting to sewing. Here your order is pieced together, as the sewers take the fabrics from the
cutting department, and sew them into cushions or slings.
After sewing, the cushion cases are filled. This machine compresses the fill, and pushes it into
the cushion cases evenly to form a smoothly shaped cushion.
Speaking of fill, you have a number of choices, depending on the cushion type you want. Foam slabs
provide a firmer cushion than polyfill, and by mixing these two fillers, we can achieve various degrees of firmness
and shape. Here you see the foam and poly storage area.
This worker is trimming poly batting in preparation for wrapping around foam slabs.
Here's what's inside our thicker, firmer cushions. You see a foam slab inside a polyfill wrap. The
foam provides the firmness, and the poly gives the cushion an initial soft feel and rounds out its shape.
Here you see workers assembling chair frames. We have a separate video that shows you how to do
this at home, step-by-step. Some furniture is delivered fully assembled, while others require some minor assembly
As you can imagine, a factory that makes and ships furniture and replacement cushions all over the
country requires a lot of storage space for raw materials and for orders that are in process. Table tops for
example, require a lot of floor space because of the wide variety of sizes and shapes. In addition, orders for
furniture and cushions take up space as they progress through pproduction.
We hope you've enjoyed this short tour. Look for other videos on this website that show exactly
what's inside specific cushions, and also how to assemble your pipe furniture order when it arrives at your