Our Process
Woodshop
A piece of furniture starts in the woodshop, where our digitized patterns are cut using a precision CNC router and hand finished.
Kingfisher frames are a combination of kiln dried hard woods and manufactured laminated hard wood. These modern hardwood frame materials allow us to create engineered frames that are precise and very very strong. Individual large frame components are glued and screwed together. Each of these large components is then bolted together to create a rigid, long-lasting frame.
Leather Cutting
While the frame is being built in the woodshop, the leathers and fabrics are running through our cutting department.
The Kingfisher cutting department uses both automated and hand-cutting methods. Our digitized patterns are precise, replicable, and also customizable.Â
Sewing
After cutting, the leather or fabric moves to our sewing area.
We use all nylon thread for strength, and use both single and double top stitch automatic sewing machines.
Upholstery
Once framing, cutting and sewing are done, everything comes together in upholstery.
We apply foam to the frame where needed for padding, add chipboard on the outside portions of the frames to keep leathers and fabrics nice and straight once upholstered, and cover the individual frame components with the required leathers and fabrics. Then the individual frame components are bolted together.
Quality Check
In QC, the final touches are added to the piece of furniture such as cushion stuffing and nail heads.
We also visually inspect and clean each piece and double check that all the correct materials were used.
Shipping
Kingfisher ships everything we build.
We do everything we can on our side to get it to you safely. The piece is hand wrapped in 1/16″ foam, and covered with cardboard, then a heavy-duty 5 mil plastic furniture bag. This completely wrapped piece is then put in a heavy-duty custom-built cardboard box with a wooden base that is strapped to a custom pallet.Â