Built for your four sizes, and for whoever opens the box.
Scoped to the four sizes on your list and nothing else. One link to forward instead of a thread to scroll back through.
Your sizes.
Confirmed with you on 19 August. All four ship as accessories or home decor.
| Size | Where it goes |
|---|---|
| 20 x 20 | Throw |
| 22 x 15 | Lumbar |
| 56 x 15 | Eclipse lumbar, sofa |
| 34 x 15 | Eclipse lumbar, chair |
Three fills, and where each one belongs.
Cut to a decorative insert rather than the whole catalogue. One of these is the answer, one is a maybe, and one we ruled out for you.
Wild-Harvested Kapok
The answer for all four
The lightest natural fiber there is. Every strand is a hollow tube that runs 80 to 90 percent air, which is what lets it sit high and stay there. A decorative insert has a job a bed pillow does not, which is to hold its shape on a sofa nobody is sitting on. Down does it and packs down over a year. Polyester does it and goes flat faster.
It also weighs almost nothing, which is the first thing a customer notices lifting it off the sofa.
See the fill →
Organic Wool
If the piece needs weight
Wool drapes where kapok springs. It moves moisture without holding it, which matters in a room that swings between seasons. It is heavier per cubic inch, so it changes how a 56 inch lumbar hangs along its length. Worth handling before you decide against it.
GOTS Certified Organic, license GOTS-10229, issued by Oregon Tilth.
See the fill →
USA-Grown Buckwheat
Ruled out, and why
Hulls hold a shape exactly and do not move. That is right under a head and wrong inside a throw pillow, because it is heavy and it makes noise when someone shifts against it.
It is on this page so you know we considered it and ruled it out, rather than never mentioning it.
See the fill →The Buckwool is in your box to show you how we build.
One insert, an internal divider, two separate materials either side of it, built to a drawing. Squeeze it along the seam and you will find where one chamber stops.
It is in the box because if any of your four sizes ever needs a firmer core inside a softer surround, that is the build, and a drawing is easier to discuss once you have held one.
The 56 x 15 is the size where this could matter for a different reason. At that length we want to confirm whether the fill needs an internal divider to stop it migrating end to end. That question is with the workshop now and the answer comes back with the quote.
Casing and closure.
Both are decisions for your production person rather than ours, so here is what each one costs you in practice.
Casing
Your samples carry two, organic cotton sateen on the kapok and organic cotton twill on the Buckwool. Since we supply the insert and your upholsterer sews the outer cover, the casing is a spec line rather than a finish. Nobody but your team ever sees it.
We are also pricing a plainer casing at these sizes, in case the sateen is paying for something that sits permanently out of sight.
Closure
Zippered lets the person who owns the sofa adjust the fill years after they bought it. It is the one that keeps the piece serviceable.
Sewn shut is cheaper and holds one fixed height for the life of the cushion.
Both are being quoted so the gap between them is a number you can see rather than a thing we argue about.
Where TB 117-2013 lands.
The 20 x 20 and both Eclipse lumbars ship as accessories and home decor, which puts them outside TB 117-2013. You confirmed that on 19 August, and it is what lets all four sizes be quoted on natural fill on your current timeline.
If the seating lines ever come into scope, the test that matters is a Section 3 on the fill itself, which is the component certificate a supplier hands a furniture manufacturer. We are pricing that test so you have a number rather than a maybe whenever you want to look at it.
We do not have smolder data on any of these fills today and we are not going to imply otherwise.
One workshop, since 1981.
Every insert is cut and sewn in our partner workshop in New Jersey, which has been building natural-fill bedding for more than forty years. Nothing is warehoused. A run is made after it is ordered, which is why the fill weight is a number you choose rather than one you inherit.
Lead time at your volume is three to five weeks. We will not confirm a delivery date until the workshop confirms it to us first.
Pricing
Being priced now: per unit across all four sizes, in both closures, at 450 to 600 inserts a year.
It lands here and in your inbox at the same time, alongside the Section 3 test price. That is the whole agenda for the call you asked for.
Name a day once the box lands.
Thirty minutes, with the quote and the test price already in front of you.
Email JacobPrepared for Sabai Design · Hudson, NY and High Point, NC
