Modular Sectional Sofa Development

A modular sectional system with 7 interlocking modules, engineered for a European online furniture brand. Each module ships in a single carton.

Edited by ryan_boss, Director of Product · August 5, 2026

Modular Sectional Sofa Development

An online furniture brand based in Amsterdam needed a sectional sofa that customers could configure online and assemble at home without tools. Our engineers developed a system of 7 modules, including armless seats, corner units, chaises and ottomans, that link with a concealed steel clip.

Each module fits in one carton under 0.45 m³ and 30 kg, meeting parcel carrier limits and reducing last-mile delivery costs. Frames combine FSC certified pine with plywood, and seats use pocket springs topped with 30 kg/m³ foam.

Development milestones

Engineering drawings and clip prototype: 6 days
Full module samples: 10 days
Drop and compression testing to ISTA 3A

The first order covered 2,400 modules across 4 fabric colors and shipped in 31 days. The brand now reorders every 6 weeks.

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