Why do modern sprung cushions have problems?

By Frank Parker

cushion upholstery Perth
cushion upholstery Perth

What are contemporary sprung cushions?

Contemporary sprung cushions have been marketed over the last decade as a superior concept however there are major issues regarding the effectiveness of using ‘spring pockets’ in the fabrication of seat cushion inserts.

How are traditional spring cushions different to modern spring cushions?

Traditional sprung cushions were constructed using mid-gauge coil springs and hand sewn into a hessian case then encased with flock and fitted into a box piped seat cushion with sewing usually finished by hand stitching. Seat cushions constructed this way tend to stand the test of time as is evident by cushions still used in antique furniture.

However the fabrication of modern sprung cushion inserts utilise light-gauge coil springs encased in a series of thin polyester pockets which are normally referred to as ‘spring pockets’. These spring pockets are placed in the centre of the cushion inserts and sandwiched with polyurethane foam then usually encased with polyester fibre. With moderate to heavy use the spring pockets tend to distort with the springs often fracturing the casings. The result is a distorted and uncomfortable seat cushion and maybe a costly repair bill outside the warranty period.

What about the option of premium quality foam cushions?

The sales personnel promoting the “advantages” of sprung cushions usually infer by definition that the base is also sprung but most sprung cushions are on bases fitted with elastic webbing. The truth is that there is nothing wrong with a settee base correctly fitted with high quality elastic webbing. However a superior cushion insert can be effectively achieved by simply using premium quality polyurethane foam encased in polyester fibre and no spring pockets!

Similar Posts

  • Re-upholster leather Tessa furniture

    Tessa Furniture is an iconic name in Australian furniture manufacturing being a prolific name during the heydays of local furniture industry. Although refurbished mid-century modernist furniture with a Scandinavian influence is a niche market the interest not only resides with those who have been fortunate to have witnessed this period of design history. Some discerning members of younger generations are purchasing or inheriting this furniture and having it restored.  

    A client approached us with her much loved Tessa leather lounge suite which she had inherited from her parents. She wanted the lounge fully restored as she remembered it growing up on the family farm.

    We completely removed all existing upholstery then sanded the frame back to bare timber. Several timber rails were re-glued then the frame was finely sanded. The Tasmanian Myrtle timber frame was then stained back to the original finish and given three coats of lacquer being lightly sanded between coats.

    The original springing systems were fine in the backs and the settee seat however new premium quality elastic webbing was fitted to the chair seats to conform to the original specifications. New channelled and quilted polyester back cushion inners were fabricated likewise new polyester encased premium polyurethane seat cushion inners. The quality of the seat and back cushion inners however far exceeded the original upholstery componentry.

    It is extremely important to use a high quality leather for the upholstery and we used the Tasman ‘Matisse Manuka’ which is a superior quality semi-aniline leather from New Zealand. All the detailed stitching was replicated and needless to say that our client was elated at the family lounge suite being returned to its former glory days.

    Call us Today
  • Club Lounge Restoration

    Restoring an Australian Club Lounge is to a furniture manufacturer as what restoring a Holden or Falcon car is to a mechanic. Various versions of this Club Lounge style were produced in Australia from the late 1920’s through to the late 1950’s. There is a special place in our hearts for this type of lounge and we always welcome the challenge when being tasked with another Club Lounge restoration.

    A young lady from Geraldton approached us regarding restoring a club lounge originally belonging to her grandparents from a farm in Mullewa which had been stored in a sheering shed for several decades being home to the resident rodents. Her parents who had since run the family farm for many years transported the lounge suite to the factory then upon arrival we could see it was basically in good structural condition and still partially covered in the tattered original upholstery fabric.

    We removed all the upholstery stripping the lounge suite down to the bare frame. The frame joints we then partially knocked apart and re-glued with a crosslinking PVA and then screwed. The timber trays and base blocks sanded back with the cracks and dents being filled with two-pack resin. They were then finely sanded and given three coats of clear lacquer.

    The upholstery started with fitting heavy weight jute webbing, lacing in the coil springs then tying down the springs and fitting hessian overlays. We then fitted synthetic edge trim and laminated high density foam to the bodywork. The back flutes were fabricated from premium foam then encased with bonded polyester fibre back to the original shapes. The seat cushions were fabricated using the same method and the outside arms and backs were all lined and padded. The fabric covering was a ‘W’ pile velvet suitable for heavy use with the upholstery finish detailed back to original finish.

    Our client was elated upon receiving her re-upholstered furniture with a comment from her parents on our Instagram “who is a lucky girl” which said it all!

    Call us Today
  • Re-styled 1940’s chairs

    Occasionally clients are unhappy with the style of the chairs presented to us for repair and re-upholstery. This can be as a result of either initial design flaws, poor re-upholstery or poor reconstruction as a result of previous damage or sometimes a combination of these factors. The idea is not necessarily to bring a chair back its purest original form but occasionally compromise with slight re-styling to compliment the client’s décor.

    These two 1940’s chairs were presented to us by a client as they had been passed down to her through the family. She wanted the chairs to be re-upholstered however she wanted the arms modified on one chair and the wings to be altered on the other chair. This re-styling was required partially due to initial design flaws but also due to past re-upholstery exaggerating these flaws.

    We completely stripped the existing upholstery on both chairs down to the bare frames. The top arms on one chair were then cut down to a cigar shaped arm in keeping with the design while the other chair had a plywood strip removed from the inside wings which improvised as a thumb roll. The two modified chair frames were then re-upholstered using a combination of traditional and contemporary methods.

    When these re-styled chairs were delivered to our client she was ecstatic with the outcome. We trust the chairs will be enjoyed and continued to be passed down to future generations.

    Call us Today
  • Sofas to Size – Reupholster

    Sofas to Size evolved from Impact Designs, a company founded in 1996. The business manufactured wholesale upholstered furniture and was located at Buckingham Drive Wangara. Then in 2005 the business name was changed to Sofas to Size and marketed direct to the public from a retail premises located on Canning Highway in South Perth.

    The concept of marketing sofas custom-made to size was an excellent concept as the business grew rapidly in a short time. Sofas to Size ceased operating in 2010.

    We were contacted by a client who purchased several settees made by Sofas to Size. These settees were identical in design and custom-made to specific lengths to suit our clients living area. They were originally upholstered in a synthetic suede but they were to be re-upholstered in a quality plain chenille.

    The existing upholstery was completely removed from the timber framed settees then new heavy grade elastic webbing was fitted and then new body-work padding was laminated onto the frames. New polyester encased premium seat cushion inserts were fabricated along with polyester filled channelled and quilted back cushion inserts. The settees were then carefully upholstered to the original finish.

    Our clients was absolutely delighted with the result of their refurbished settees saying they were designed for the room and they still looked perfect for the room.

    Call us Today
  • Re-upholster antique chair in linen

    The use of different upholstery materials can totally transform the appearance of a chair. You may have inherited a chair or just have seen an antique chair where you admire the design but have to use your imagination regarding a suitable fabric for re-upholstery which would suit your décor.  In this situation take your time to investigate the possibilities and possibly consult with an upholsterer experienced in this area of work.   

    A client came to see us from the South West farming town of Boyup Brook as they had inherited chair from the United Kingdom made in the 1880’s. This chair had sadly resided in their shed for many years and was in a dilapidated state having been previously in leather. They wanted this chair to be re-furbished for their bedroom so a Heritage Linen with a matching soft pink cotton velvet for piping.

    The existing upholstery was completely stripped to the frame then structural repairs carried out and the legs re-polished. We then fitted jute webbing, laced and tied down coil springs with hessian overlays. The shapes were then developed utilising modern polyurethane furniture edging instead of fibre fill stitched edges and premium high density foam instead of the traditional flock and fibre. We feel that using this combination of traditional and modern methods of building the upholstery foundation gives an authentic finish with superior comfort.

    The chair was then upholstered a high quality screen printed vat dyed linen with a matching pink cotton velvet piping. This gave a softer appearance to the chair which was required by our client. This chair having been constructed in the 1880’s was now rejuvenated by descendants of the original owners and functional in 2019!

    Call us Today
  • Custom Upholstery

    This custom-made dining lounge was designed and manufactured by a cabinet making firm then upholstered by a local upholstery business. The frame was well designed and constructed however there were continual substantial issues with the upholstery. Unfortunately this is something that occurs to often in our industry. 

    A client approached us saying she had a custom-made dining lounge and there were substantial issues with the upholstery and she had given up trying to negotiate any solution with this upholstery business. The entire front edge of the seat had collapsed and buttons which she did not want but were initiated by the upholstery firm had ‘popped’. Our client engaged us to completely re-upholster this dining lounge.

    We completely removed the existing upholstery and discovered the problems causing the clients concerns. The previous upholsterers had used high quality foam on the seat however they had used a water based contact adhesive to which there are still major application problems and is was simply just not effective. Also the reason they had to place buttons into the seat and back panels was that the patterns were not true to the frame sizes causing the cushions to distort.

    We started from scratch making templates true to the frame then fabricated premium cushioning and laminated it with bonded polyester fibre. The cushion covers were then carefully marked with sewing indicators and sewn to shape as such large panels can either be stretched or gathered. The lounge was then upholstered with minimal effort as the fabric covers fitted perfectly.

    The result was that our client was absolutely overwhelmed with the result and we have since received repeat work from her. This just goes to show that quality work is always the best form of advertising and everyone is a winner.

    Call us Today