Our Workshop · Lahore
How an AM Sofa Studio sofa is actually built, step by step.
The workshop is in Lahore. The wood is kikkar. The foam is Mastermolty. The joinery is mortise-and-tenon. Below is the full five-stage build process every custom piece goes through before it ships.
- 01
Frame cut from seasoned kikkar wood
Our timber arrives kiln-dried to under 12% moisture and rests in the workshop for two weeks before any piece is cut. We size every panel against the customer's spec sheet — not a generic stock cut — and finger-joint the rails in-house. No engineered wood, no MDF, no plywood load-bearing pieces.
- 02
Mortise-and-tenon joinery
The four load-bearing corners of every frame use mortise-and-tenon joints, glued with PVA wood glue and reinforced with hardwood corner blocks. Screws are used for trim only. This is the joint your grandparents' sofa used and it's why their sofa is still standing.
- 03
Webbing, springs and foam stack
Seat platforms use criss-cross jute webbing under an 8-gauge S-spring deck, finished with high-resilience Mastermolty foam at 28 to 32 kg/m³ for seats and 22 kg/m³ for backs. Backs and arms are wrapped in dacron for that pillow-soft feel that doesn't collapse.
- 04
Upholstery — Faisalabad mills, hand-cut
Fabric is cut by hand from the bolt. Patterns are matched at the seams so a chesterfield's buttoning lines up with the back panel. Every panel is sewn with bonded polyester thread rated for furniture use.
- 05
QC, photography, and the truck
Before a sofa leaves the workshop it sits for 24 hours under inspection. We photograph the finished piece and send it to you on WhatsApp before scheduling delivery. Every Lahore delivery goes out on our own vans — free across every neighborhood, no minimum.
Frequently asked about the workshop
- Can I visit the workshop?
- Yes. We host showroom visits at the Lahore workshop by appointment, Monday to Saturday 11am to 8pm. Message us on WhatsApp at +92 323 0180873 to book a slot.
- Can I see my sofa being built?
- Absolutely. We send WhatsApp progress photos at three stages: frame complete, foam fitted, and final upholstery. You can also visit in person at the foam-fit stage to test the seat firmness before we commit to upholstery.
- Do you make repairs or reupholster old sofas?
- Yes. We strip down old sofas to the frame, replace foam, webbing and fabric, and ship back like new. Pickup-and-return within Lahore is free.
- How many craftsmen does AM Sofa Studio employ?
- The Lahore workshop runs with a head karigar (master upholsterer), four senior craftsmen, two apprentice tailors and a frame-maker — eight pairs of hands on every piece that leaves the building.