Extrusion Velvet Sofa

Aandersson

DIY velvet sofa couch designed by Aandersson
DIY velvet sofa couch designed by Aandersson
Extrusion Velvet Sofa

Design and photography by AANDERSSON
Published in Spring 2019

This sofa employs one of the simplest production processes of any structured and refined sofa in production today. The design is a result of countless compromises, experiments, and simplifications to distill the assembly to 24 steps that can be done within the course of about 6 hours by anyone that has the right tools and enthusiasm. The 26 pieces of lightweight aluminum framing can be completely taken apart and re-assembled in 30 minutes for easy moving. Parts for this difficult to assemble design cost on average 700 USD.

DIY velvet sofa couch designed by Aandersson
DIY velvet sofa couch designed by Aandersson
DIY velvet sofa couch designed by Aandersson
DIY velvet sofa couch designed by Aandersson
Assembly
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1     To assemble the frame with the small brackets, first slide the bracket onto the channel of each frame piece.
1     To assemble the frame with the small brackets, first slide the bracket onto the channel of each frame piece.
2     Then, when the frame is in place, firmly tighten the bolts on the small bracket with a hex key.
2     Then, when the frame is in place, firmly tighten the bolts on the small bracket with a hex key.
3     To attach the large brackets to the frame, first slide the spring-loaded nuts in place as pictured.
3     To attach the large brackets to the frame, first slide the spring-loaded nuts in place as pictured.
4     Then arrange all 4 nuts in the channels of the frame so that they line up with the holes in the large bracket.
4     Then arrange all 4 nuts in the channels of the frame so that they line up with the holes in the large bracket.
5     Then, insert the screws through the holes in the bracket and firmly tighten with a hex key.
5     Then, insert the screws through the holes in the bracket and firmly tighten with a hex key.
6     Arrange the following pieces of the frame on a large flat space as pictured. Four 1070mm pieces, Five 730 mm pieces, and Six 300mm pieces. Take care not to scratch the frame.
6     Arrange the following pieces of the frame on a large flat space as pictured. Four 1070mm pieces, Five 730 mm pieces, and Six 300mm pieces. Take care not to scratch the frame.
7     Secure the frame with small brackets where the arrows are pointing in the picture.
7     Secure the frame with small brackets where the arrows are pointing in the picture.
8     Repeat step 7 for the other side of the frame you have laid out. Also, place 1 large bracket on each of the 300mm parts in the center of the frame (shown at the top of the picture).
8     Repeat step 7 for the other side of the frame you have laid out. Also, place 1 large bracket on each of the 300mm parts in the center of the frame (shown at the top of the picture).
9     Tilt the frame you have assembled so far on its side, and place two 1070mm pieces and one 300mm pieces next to the frame as pictured. Secure them with two small brackets (see arrows) and one large bracket (see circle).
9     Tilt the frame you have assembled so far on its side, and place two 1070mm pieces and one 300mm pieces next to the frame as pictured. Secure them with two small brackets (see arrows) and one large bracket (see circle).
10     With a hand saw, trim your MDF board so it is only 108cm (42.5in) in length.
10     With a hand saw, trim your MDF board so it is only 108cm (42.5in) in length.
11     Stand the frame on its feet and place the MDF boards in the channels in the middle of the frame.
11     Stand the frame on its feet and place the MDF boards in the channels in the middle of the frame.
12     Arrange one 730mm piece, one 790mm piece, and two 630mm pieces as pictured. The top side of the 730mm piece should be placed exactly 300mm (11.8in) from the top of this arrangement. Also, position small brackets on the frame as pictured and noted by the L diagrams.
12     Arrange one 730mm piece, one 790mm piece, and two 630mm pieces as pictured. The top side of the 730mm piece should be placed exactly 300mm (11.8in) from the top of this arrangement. Also, position small brackets on the frame as pictured and noted by the L diagrams.
13     Repeat step 12 with four new frame pieces. The positioning of the small brackets will be the only difference with this step.
13     Repeat step 12 with four new frame pieces. The positioning of the small brackets will be the only difference with this step.
14     Attach your assemblage from step 12 to the frame you have assembled so far. Slide the MDF board into the channel and tighten the small brackets (see arrows). Make sure everything lines up nicely.
14     Attach your assemblage from step 12 to the frame you have assembled so far. Slide the MDF board into the channel and tighten the small brackets (see arrows). Make sure everything lines up nicely.
15     Repeat step 14 on the other side of the frame you have assembled so far with your assemblage from step 13. Also, wedge folded pieces of paper in the frame to keep the MDF board from sliding around and sand down any raw cut edges of aluminum on the frame.
15     Repeat step 14 on the other side of the frame you have assembled so far with your assemblage from step 13. Also, wedge folded pieces of paper in the frame to keep the MDF board from sliding around and sand down any raw cut edges of aluminum on the frame.
16     On all of the 10 legs of the frame, stick felt bumpers.
16     On all of the 10 legs of the frame, stick felt bumpers.
17     Cut two pieces of velvet fabric in each of the following dimensions: 62in x 44in (158cm x 112cm), 48in x 37in (122cm x 94cm), 48in x 44in (122cm x 112cm). So, you should have cut 6 pieces in total.
17     Cut two pieces of velvet fabric in each of the following dimensions: 62in x 44in (158cm x 112cm), 48in x 37in (122cm x 94cm), 48in x 44in (122cm x 112cm). So, you should have cut 6 pieces in total.
18     Fold each piece in half, with the velvet on the inside, so two measure 31in x 44in (79cm x 112cm), two measure 24in x 37in (61cm x 94cm), and two measure 24in x 44in (61cm x 112cm). Sew, either by hand or with a machine, 1in (2.5cm) from the edge along the black line in the photograph (the folded edge of the fabric is the long side on the right).
18     Fold each piece in half, with the velvet on the inside, so two measure 31in x 44in (79cm x 112cm), two measure 24in x 37in (61cm x 94cm), and two measure 24in x 44in (61cm x 112cm). Sew, either by hand or with a machine, 1in (2.5cm) from the edge along the black line in the photograph (the folded edge of the fabric is the long side on the right).
19     Take one corner and line up the seams so that they are exactly in the middle of the corner. Sew across, as pictured, so that your sewing line is exactly 5in (13cm) long from one end of the fabric to the other.
19     Take one corner and line up the seams so that they are exactly in the middle of the corner. Sew across, as pictured, so that your sewing line is exactly 5in (13cm) long from one end of the fabric to the other.
20     Repeat this process for the remaining 3 corners and the remaining 5 pieces of fabric. To visualize how this will affect your fabric's shape before you sew, pin or clip along the sewing lines and turn the fabric inside out.
20     Repeat this process for the remaining 3 corners and the remaining 5 pieces of fabric. To visualize how this will affect your fabric's shape before you sew, pin or clip along the sewing lines and turn the fabric inside out.
21     Cut out pieces of batting that wrap fully around the length of the foam cushions, as pictured. The batting should not cover much, if any, of the shorter sides of the cushion, as pictured.
21     Cut out pieces of batting that wrap fully around the length of the foam cushions, as pictured. The batting should not cover much, if any, of the shorter sides of the cushion, as pictured.
22     Turn your sewn fabric inside out and stuff each cushion cover with the appropriately sized foam cushion wrapped in batting.
22     Turn your sewn fabric inside out and stuff each cushion cover with the appropriately sized foam cushion wrapped in batting.
23     Fold excess fabric under and staple or sew (sewing is preferred) opposite strips of Velcro to the open area of the cushion covers as pictured. Add these about every 2in (5cm).
23     Fold excess fabric under and staple or sew (sewing is preferred) opposite strips of Velcro to the open area of the cushion covers as pictured. Add these about every 2in (5cm).
24     Select a few Velcro strips to extend and attach a long piece of Velcro. Glue opposing sides of Velcro in the same length to the MDF board and attach the Velcro from the cushion to the board. This should will help keep the cushions from sliding out of place.
24     Select a few Velcro strips to extend and attach a long piece of Velcro. Glue opposing sides of Velcro in the same length to the MDF board and attach the Velcro from the cushion to the board. This should will help keep the cushions from sliding out of place.
Index
Parts
Anodized T-slotted Aluminum Frame, 30mm x 30mm
Quantity required: 6 x 1070mm length, 7 x 730mm length, 7 x 300mm length, 2 x 790mm length, 4 x 630mm length
Large T-slotted Framing Gusset Bracket
Quantity required: 3
Small T-slotted Framing L-shaped Bracket
Quantity required: 50
Felt Bumper, 3/4in (2cm)
Quantity required: 10
MDF Board, 1/4in (8mm) thick, 2ft x 4ft (61cm x 122cm)
Quantity required: 2
HD36 High Quality Cushion Foam, 5in (13cm) thickness
Quantity required: Two of each: 25in x 37in (63cm x 94cm), 18in x 30in (46cm x 76cm), 18in x 37in (46cm x 94cm)
Polyester Fiberfill Batting, 60in x 15ft (1.5m x 4.5m), 1in (2.5cm) Thick
Quantity required: 1
Hook and Loop (or Velcro), 3/4in (2cm) wide, 15ft (4.5m) long
Quantity required: 1
Velvet Upholstery Fabric, 10yd (9m), Slate Blue
Quantity required: 1
Tools
Hex Keys, M6 and M5
Hand Saw
Sewing Machine or Sewing Needles
Gutermann Extra Strong Thread
Clear 5 minute Epoxy Glue
Alternative Parts
Velvet Upholstery Fabric, 10yd (9m), More Colors
Replaces: Slate Velvet Upholstery Fabric, 10yd (9m)
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