Sustainable furniture: How we build Casquet - 100% ecological and plastic-free sofa - part 5/6

by tine sintermann on December 09, 2020

Sustainable furnitureSustainable Sofa Ecofriendly Sofa MakingPart 4 of making sustainable furnitureEcofriendly furniture from D3CO in MilanPart 6: Finalizing our sustainable and ecofriendly sofa Casquet at D3CO Workshop Milan

 

Sustainable furniture for your home: non-toxic and plastic free sofa

Part 5: Inside and outside cover

Building a sustainable piece of furniture takes experience, craftsmanship and in our case: an extra dose of 100% natural materials from only sustainable sources. We chose to build furniture only in this way, because we believe that we should not live with, or sit and sleep on anything that is built using harmful materials. Harmful for nature, our environment or our own health.

 

The sofa we are building in this series is our 2 seater sofa Casquet - and if you’ve followed our previous ‘Making Of’s’: it is coming to life quite nicely. We envisioned and designed the product, built the wooden frame and added layers of comfort by using 100% natural latex, cotton and jute. Now we are going to apply extra layers of textiles.

Making of sustainable sofa Casquet - ecofriendly and plastic-free furniture from D3CO

Using highest quality textiles and precision cuts

Thanks to our 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 for larger furniture pieces such as modular sofas, 3-seater sofas and more. After the textile is perfectly placed on the cutting table, gentle air pressure from underneath starts to suck the textile down, holding it in place during the whole cutting process.

Making of sustainable sofa Casquet - ecofriendly and plastic-free furniture from D3CO 

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 our experience in working with textiles of all sorts, we will make sure that the surface will look even in the end result of the finished piece of furniture.

 

Making of sustainable sofa Casquet - ecofriendly and plastic-free furniture from D3CO

Cleaning up and preparing for the final touches

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. The first cover is a white protective cover and will also support the final textile to run smoothly and perfectly flat. When you remove your top textile cover from your furniture for cleaning purposes (removing our textile covers is something we’re quite proud of to offer as a standard), you’ll see exactly this cover. 

Making of sustainable sofa Casquet - ecofriendly and plastic-free furniture from D3CO

Making of sustainable sofa Casquet - ecofriendly and plastic-free furniture from D3CO

Finally, the textile you chose as your top cover is coming into play. To avoid shrinking due to cleaning, we pre-wash it for you, then cut and sew it to perfectly match your furniture. Removing your textile cover is quite easy and done by opening our steel and cotton zippers and / or removing small metal clips or wooden fastenings on the bottom of the sofa. Even though our materials are proven and robust, you might want to clean it from time to time or repair it when damage happens. We ourselves have many kids in our Italian families, and we know how quickly a gelato can drip onto a cushion by accident. In any case you won’t have to throw the cover or the furniture away!

Making of sustainable sofa Casquet - ecofriendly and plastic-free furniture from D3CO