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.