1. Design & Planning

Before production starts, manufacturers decide:

Diameter and height

Shape (flat top, tufted top, pouf style, skirted, etc.)

Materials: wood frame, foam density, fabric or leather upholstery

Style details: buttons, nailhead trim, stitching, legs

This design becomes the blueprint.

2. Frame Construction (Structure of the Ottoman)
A. Cutting the Base & Top

Two circular wooden panels (MDF, plywood, or solid wood) are cut.

These become the top surface and bottom base.

B. Building the Cylinder

To create the round body:

Wood slats, plywood strips, or a curved wood ring are bent/formed into a circle.

These pieces are attached between the top and bottom panels.

Internal support blocks or braces are added for strength.

This creates a strong cylindrical frame.

3. Adding Padding (Foam & Cushioning)
A. Foam Application

A circular foam pad is cut for the top.

Additional foam is wrapped around the sides (the cylinder).

Foam is glued or adhered to the wood frame.

B. Adding Batting

Polyester batting is wrapped around the foam for smoothness.

This prevents fabric from wrinkling and gives the ottoman its soft feel.

4. Upholstery Work (Covering the Ottoman)
A. Cutting Fabric or Leather

Fabric/leather pieces are cut to fit the curved shape.

Side panels are cut as long strips that will wrap around the ottoman.

The top circle is cut to match the diameter.

B. Attaching Upholstery

Fabric is stretched tightly over the top and stapled underneath.

Side fabric is wrapped around the cylinder and smoothed to avoid wrinkles.

Excess folds are trimmed and stapled securely on the underside.

C. Tufting (Optional)

For tufted designs:

Holes are drilled in the frame top before foam is applied.

Buttons are threaded through fabric and pulled tight to create tufted dimples.

5. Adding Legs or Base

Depending on the style:

Wooden legs are screwed into preinstalled mounting plates.

Metal legs are bolted on.

Some ottomans have no legs (pouf style) and sit flat on the floor.

Others have a solid plinth base.

6. Underside Finishing

The bottom is finished by:

Adding a dust-cover fabric (black or matching color).

Stapling clean edges around the frame.

Ensuring no exposed staples or rough wood.

7. Quality Check & Finishing Touches

The ottoman is inspected for:

Smooth, wrinkle-free upholstery

Even shape

Strong, stable structure

Comfort and firmness

Decorative accents (nailheads, piping, buttons)

After passing inspection, it’s packaged and ready to ship.