Unstapled and Refoamed
Redesigning Couches for Disassembly, Reupholstery and Foam Replacement
A.L. Jonkman (TU Delft - Industrial Design Engineering)
J.I.J.C. de Koning – Graduation committee member (TU Delft - Industrial Design Engineering)
S.F.J. Flipsen – Mentor (TU Delft - Industrial Design Engineering)
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Abstract
Couches are frequently discarded while their frames, suspension systems and other structural components still retain functional and economic value. Refurbishment could extend product lifetimes, but current couch constructions make the main wear components, particularly foam and upholstery, difficult and labour intensive to access and replace. This graduation project investigated which product design interventions could enable furniture producers to repair and refurbish their own couches more efficiently.
The research was conducted in collaboration with The Bin and Dutch Quality Group. The analysis identified glued foam and difficult to remove upholstery as the main product level barriers to refurbishment.
Two design principles were developed. The first divides the seat foam into interlocking compartments, allowing worn areas to be replaced locally. The second uses a pullcord to tension and release the upholstery without destructive fastening. These principles were combined in a demonstrator cushion with replaceable foam blocks, a flexible felt inlay and a reversible fabric cover.
The comparison indicates that replacing one third of the foam could reduce the estimated refurbishment time from 48 to 36 minutes, lower costs by approximately 45 to 50 percent and require 67 percent less new foam than full cushion replacement. An indicative climate impact comparison estimates that approximately 447 kg CO₂ equivalent could be avoided for two couch modules over three life cycles. However, the demonstrator increases initial production costs and has not yet been validated for long term comfort, durability or industrial production.
The project concludes that the developed concepts are most relevant to high quality couches with sufficient residual value to justify refurbishment. More broadly, it demonstrates that refurbishment can be supported by treating foam and upholstery as accessible wear components that can be inspected, removed and replaced without damaging the remaining product.