1. Design and Planning

The process begins with creating the ottoman’s design, including size, shape, style, and materials.

Designers choose fabric types, cushion thickness, leg style, colors, and any decorative elements (tufting, stitching, buttons).

Technical drawings and measurements are finalized before production starts.

2. Frame Construction

The internal frame is usually built from wood, plywood, or engineered wood.

Workers cut and assemble the pieces into a sturdy box-like structure.

Support braces may be added to improve durability and weight capacity.

3. Cushion and Padding Preparation

Foam, sponge, or fiberfill is cut to match the top shape of the ottoman.

Additional padding may be added to the sides for comfort and aesthetics.

For tufted styles, holes are pre-marked for button placement.

4. Upholstery Work

Fabric or leather is measured, cut, and sewn according to the design.

The upholsterer stretches the material tightly over the frame and padding, securing it with staples or upholstery tacks.

Decorative details like stitching, piping, tufting, or buttons are added during this step.

5. Attaching Legs or Base

Wooden, metal, or plastic legs are installed at the bottom of the ottoman.

Some models have a solid base instead of legs, while others use casters (wheels) for mobility.

The legs are secured using screws or bolts for stability.

6. Quality Check and Finishing

The ottoman is inspected for stability, smooth upholstery, stitching quality, and overall appearance.

Final touch-ups are made, such as trimming excess fabric, tightening screws, or cleaning the surface.

The ottoman is then packaged and prepared for shipping.