Article: How Our Booths Are Made — Inside the Workshop
How Our Booths Are Made — Inside the Workshop
Behind every booth we make is a team of skilled craftspeople, modern tools, and decades of upholstery know-how.
At The Booth Co, nothing is mass-produced. Every piece is handcrafted to order in our British workshop, built with precision from the ground up.
Here’s a look at how your booth comes to life — step by step.
The Design Process
It starts with you. Once we receive your measurements or 2D CAD layout, our design team finalises every detail — from dimensions and plinth finish to fabric choice and seat depth.
You’ll receive a clear visual of your booth before production begins, ensuring a perfect fit for your space.
Precision Frame Building
Every booth starts with a solid hardwood frame, cut and assembled in-house.
We use responsibly sourced timber from FSC®- and PEFC-certified suppliers, guaranteeing sustainable materials and long-term strength.
Each joint is glued, screwed, and reinforced for decades of daily use — the same commercial-grade construction we supply to restaurants across the UK.
From Frame to Foam — The Foundations of Comfort
Once the hardwood frame is complete, it’s passed to our foamer — the person responsible for shaping comfort into every booth.
They cut and fit layers of high-density CMHR foam, bonding each section precisely to match the seat and back contours. This stage defines how the booth will feel — firm and supportive where it needs strength, softer where it needs comfort.
Our foamer trims and sands the foam perfectly flush, preparing the booth for the next stage: upholstery. It’s a hands-on process that takes patience, accuracy, and a practiced eye for detail.
Sewing & Pattern-Making — Creating the Perfect Covers
While the frames and foam are being built on the workshop floor, our fabric sewer is busy working on the upholstery covers that will bring the booth to life.
Each cover is hand-cut, measured, and stitched using industrial sewing machines — tailored precisely to match your booth’s dimensions. Depending on your design, this might mean plain, fluted, or quilted backrests, each sewn with accuracy so that every seam lines up perfectly when fitted later.
The sewer prepares every section — seat, back, and sides — ready for the upholsterer to assemble and fit. It’s the stage where the craftsmanship in the stitching sets the standard for the flawless finish that follows.
Upholstery & Finishing — Where Everything Comes Together
Once both the frame and foam are ready, and the covers are complete, everything comes together in our upholstery bay.
Our upholsterer carefully fits each fabric cover onto its booth frame, aligning every seam and smoothing each curve by hand. Using a mix of tension, heat, and precision, they pull the material snug over the foam until it sits perfectly.
This is the final transformation — where raw materials become a finished piece of furniture. Every booth is checked for clean lines, consistent tension, and that signature Booth Co handcrafted finish before moving on to quality control.
Final Assembly & Quality Control
Before leaving the workshop, every booth undergoes a detailed multi-point inspection.
We check alignment, stitching, and lift-up mechanisms, ensuring everything operates smoothly and meets our quality standards.
Each booth is then signed off by our head craftsman and prepared for dispatch.
Delivery, Installation & Aftercare
Our professional two-man delivery team brings your booth directly to your home, installs it neatly in under an hour, and removes all packaging.
We also provide aftercare guidance to help you maintain your booth for years to come.
Every piece we make includes a 10-year structural guarantee — proof of the confidence we have in our craftsmanship.
British Craftsmanship, Built to Last
From design to delivery, every stage happens right here in Britain.
By choosing The Booth Co, you’re supporting UK manufacturing, local skills, and sustainable production — while investing in furniture made to outlast trends.
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