Design


We wanted the sofa to be elegant and timeless, yet comfortable. A design that is evidently contemporary, but would never go out of style. A sofa that was more delicate in appearance than its formidable construction. We weren’t trying to reinvent the wheel, but wanted the design to be distinctly ours. From its custom T-shaped legs, to the unique choice of mixed-media upholstery, the Truss design is slightly left of center with just a few unexpected details.

The sofa also needed to be equally suited for lounging on lazy mornings and for entertaining in the evening. We spent quite a bit of time refining the proportions (3 or 4 rounds of prototyping, to be exact), allowing enough depth to fully sink in, but also the proper pitch for sitting upright.
We spent quite a bit of time refining the proportions (3 or 4 rounds of prototyping, to be exact), allowing enough depth to fully sink in, but also the proper pitch for sitting upright.
Premium Materials


After exploring hundreds of options, we landed on premium leathers from an Italian tannery. We wanted a supple hand with a more natural finish – ones that would age nicely, and embrace the organic qualities of leather. All of the leathers we selected are either full or semi aniline, which refers to the solubility of the dye. This process also maintains the natural grain pattern of the leather, only possible with super high-quality hides.

The fabrics we assorted are by a celebrated American mill, Maharam, founded in 1902. We fell in love with the rich and varied color palettes, and were sold on their durability and sustainable sourcing methods. With a 100K rub count (a metric used to determine how long the fabric can last before it pills), we wanted fabrics that had a soft hand and wouldn’t start to nap after only a few months.
After exploring hundreds of options, we landed on premium leathers from an Italian tannery. We wanted a supple hand with a more natural finish…
When touring the factory, I found the pattern-cutting on the of the most fascinating parts. Our factory USES digitized patterns and laser cutting to map each pattern onto the fabric or leather. Given the natural imperfections of leather, patterning becomes a little tricky. To ensure no imperfections make it onto a finished sofa, a skilled factory worker carefully inspects each hide and marks every imperfection using chalk.

The laser cutter then maps the pattern onto each hide in order to avoid those marked imperfections, while maximizing the leather’s yield. This innovation is the main reason why we’re able to offer our leather sofas at their comparably low price – the quoted leather yield of our factory was a good 25-50% higher than other factories we had toured.

The production manager also explained the huge importance of foam to a sofa’s endurance. We selected a 1.8 ILD commercial grade foam, which means that it will maintain its buoyancy even after years of heavy use. With lower density foam, they easily start to deflate after a few too many Sunday mornings.
This innovation is the main reason why we’re able to offer our leather sofas at their comparably low price – the quoted leather yield of our factory was a good 25-50% higher than other factories we had toured.



Construction


Before beginning this process, I can’t say that I fully understood (or appreciated) the amount of work that went into producing a sofa. But after meeting with some 30-odd factories, I not only have a newfound appreciation, but I’m also able to discern the differences that contribute to varying levels of quality. We ended up selecting a factory based in Southern California. We were super-impressed by their end product and their carefully organized processes. The manufacturer combines old-school craftsmanship with the efficiencies and precision afforded by the most advanced modern technology.
We ended up selecting a factory based in Southern California. The manufacturer combines old-school craftsmanship with the efficiencies and precision afforded by the latest in modern technology.
Our frames are all constructed using Kiln-dried hardwood, chosen both for durability and its sustainability (the wood is harvested from replenished forests, certified by the Sustainable Forestry Initiative).

The wood is cut by a CNC mill, programmed by a CAD-engineered design. This is one example where a machine far supersedes any human’s ability in both precision and speed. Once cut, however, the pieces are then assembled by a team of craftsmen who glue and clamp every joint. In addition to its double-dowel joint construction, gluing and clamping is one of the most important steps to ensuring the sofa’s lifelong durability. We also reinforced its base with steel to leave zero room for compromise. At the end, we were so confident with the sofa’s construction that we decided to offer a lifetime warranty on its frame.




We also reinforced its base with steel to leave zero room for compromise. At the end, we were so confident with the sofa’s construction that we decided to offer a lifetime warranty on its frame.
Upholstered by Hand


The final steps can only be done with the touch of a human hand. Once the frame is built and patterns cut, the sofa moves onto upholstery. A highly skilled team of sewers and upholsterers ensure that the sofa’s exterior lives up to the quality of its foundation.


Direct to You


And voila – a Truss sofa is born! A true labor of love from concept to construction. But as mentioned before, it was important for us to offer a luxury-quality product without a completely inaccessible price, so we made the decision to sell the product exclusively through TRNK. This allows us to avoid the traditional retail markup and to create a product with a truly compelling value.

We hope you love the Truss sofa and much as we do, and hope you consider making it a part of your everyday!

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