A sofa purchase is a big commitment. It’s one of the biggest pieces of furniture you will buy for your home. You want it to look great, last a long time, and stand up to wear and tear. So before you buy a sofa, consider the following:
What materials are used to make the sofa? Less expensive materials include pressboard, inferior plywood, or density fiberboard. Some sofas even contain cardboard. The sofas we recommend are made either from solid wood, the highest quality being maple, walnut, alder, teak, and poplar. These woods are kiln-dried. Other materials include strong plywood or sturdy steel.
How is the sofa put together? Avoid glued joints. The most durable, long-lasting sofas are framed using mortise-and-tenon joinery and usually have the highest price point. Still, you can find a sturdy sofa where the joints are held together by a combination of glue, dowels, and staples, but reinforcing blocks should also be used at the joints.
While cushions matter for comfort, the springs are what make a sofa comfortable. Choose eight-way hand-tied springs over drop-in or pocket-coiled springs. Some good sofas utilize polypropylene webbing in place of springs, but it must be done in a very specific way to hold up.
The best sofas make their cushions from either high-density polyurethane foam, from down, or from a combination of the two. The foam and/or down are wrapped around an innerspring core, kind of like a mattress.
What’s your style? Maybe you’re like I am and the answer changes daily. That’s okay, but you have to choose something you like, right? Consider the arms: are they rolled, straight, flat, or something else? Do you want buttons? How about a skirt on the bottom of the sofa? Should your cushions feel soft and cushy or firm? Obviously, there’s a lot to consider when choosing a sofa. Thankfully, companies who make their sofas in the USA can help you select the one that you’ll enjoy for a long time.
Not only should you think about the color of your upholstery, but also the type of fabric and its weave. Choose textiles with a high number of long threads and tight weaves. Also, look for stain-resistant fabrics. Leather obviously costs more but lasts longer than fabric. Even though it's a natural product, there are different types of leather used to make sofas. Avoid the descriptor, “genuine leather,” because it typically refers to pieces of leather glued together. Full-grain or full top-grain is the best option for a leather sofa, with top-grain more reasonably priced.
Other Sofa-Buying Considerations
You may want to think through a couple of other ideas regarding your sofa purchase:
Customization: A custom-made sofa used to mean you are requesting something different from what furniture typically offers. You want a particular style in a specific color but with a different trim package, for example. Today, many furniture companies offer only made-to-order sofas. You choose everything you want, and then the company makes the sofa. This is a much more common shopping experience.
Shopping Experience: You can shop for your sofa in several ways. One way is to shop exclusively online. Educate yourself on what you want in your sofa, then find the company that makes it that way. Other manufacturers require you to shop through a local furniture store that carries their particular brand. The nice thing about this experience is you get to go sit on various sofas and see the fabrics up close. Some manufacturers offer both shopping experiences.
Many reasons exist for buying an American-made sofa, the least of which is the cost (but that’s important, too). I list several important reasons below, in no particular order.
I’ve talked to many customer service representatives, both over the phone and online, from places other than the United States. Some are unhelpful while others are downright rude. I once even had someone email me in all capital letters like he/she was yelling at me! A number of companies don't even acknowledge me. On the other hand, most customer reps from American companies realize their reputation is on the line. They’re both helpful and friendly. I’ve found many made-in-the-USA companies’ responses come from the owners or high-level executives themselves. They’re patient in answering all my questions. They’ll even throw in a joke or kind word for free!
Companies who make their sofas in the USA take planet conservation seriously. Not only are they using sustainable methods in sourcing their materials, but they also reduce the carbon footprint in their shipping. Your goods aren’t traveling 13,000 miles across continents and oceans.
Makers of sofas care about supporting towns by employing local, skilled artisans and paying them livable wages. A strong local economy translates into satisfied individuals and thriving communities. Who doesn't want to be part of someone else's joy?
Not all, but many sofa manufacturers offer free or reasonably-priced shipping. They’ve found ways to minimize packaging.
While performing research on made-in-the-USA sofas, I discovered they’re no more expensive than any other sofa. Of course, you have your designer sofas and those who cater to wealthy markets, and they’re included in my list. But you’ll be happy to shop for American-made sofas that carry affordable prices.
The Difference Between “Assembled,” “Designed,” and “Made”
When searching for anything made in the USA, including sofas, you’ll come across certain sentences such as “Assembled in the USA” or “Designed in the USA.” You also will read something like, “Based in [a USA state],….” These sentences are often misleading because the company wants you to think their products are made in the USA when they're not. The words to look for in shopping for an American product is “made in the USA.” These words should reflect the Federal Trade Commission’s definition of a true made-in-the-USA product.
About North Carolina’s Furniture-Making Industry
When you read through the list of sofas made in the USA, you’ll see that a majority of the sofas are made in North Carolina, particularly in Hickory and surrounding towns. This is not a coincidence. This area, known as the “Furniture Capitol of the World,” is steeped in a culture-rich history of furniture making, along with generations of talented craftspeople who know how to make beautiful pieces. Obviously, the area is full of natural resources (trees) for making furniture.
In the later years of the 1900s and the turn of the century, many manufacturers closed their doors, outsourcing their production to overseas locations that offered higher profit margins to the companies. Companies closed and layoffs occurred, resulting in withering economies and morale. Furthermore, the furniture’s quality suffered, and so did each company’s reputation.
Today, by enlisting lean manufacturing methods, consolidation of companies, a commitment to local towns and economies, and a can-do spirit, we’re experiencing an uptick in American-made furniture. Let’s support our friends and neighbors by buying American-made!
Allform custom makes its modular sofas, loveseats, and sectionals in the USA using a multi-generation family-owned facility in North Carolina. These modular design offerings include a loveseat with a chaise, something you don’t see a lot of in the furniture industry. Allform also has a nice selection of fabrics. Give their products a 100-day trial use for free. Allform offers frequent sales and competitive pricing, even interest-free financing!
American Leather furniture is crafted in Dallas, Texas. The company invests in master leather craftsmen for making some of the highest quality leather sofas and sectionals you can find. Its frames are constructed from sustainably harvested wood and are precision-engineered to create as little waste as possible. American Leather also uses water-based glues and formaldehyde-free products. Visit the American Leather website to find your local retailer.
Type “Sofa made in USA” into Apt2b’s search link, and you’ll get close to 700 hits. The bad news is the website lists sofas NOT made in the USA, so check the product descriptions. The great news is this web-based company does have plenty of American-made sofas for you to choose from. Some are ready to ship, while others require a two-week window for construction. Apt2b offers plenty of online sales, and you also get free delivery and 100-day returns.
Benchmade Modern will make your sofa or sectional within as little as two weeks! Choose from traditional to ultra-modern and everything in-between; choose your sofa size and fabric, then let Benchmade Modern do the rest in either of its Los Angeles or Dallas production facility. Benchmade Modern helps you choose from its whimsical names such as “Couch Potato,” “OG Crowd Pleaser,” and more. Find leather, performance fabrics, velvet (luxurious!), and other fabric offerings.
While Bend Goods made its name on its metal furniture, those products are made overseas. However, you can buy sofas and sectionals from this California-based company that are made on American soil. The modular design offers a myriad of color and fabric options. If you’re like our family, the modular style affords you the ability to move furniture around and re-configure your living room. Bend Goods has a cool back story, and my email interaction is a testament to its quality customer care.
Bradington-Young makes luxury leather sofas in Hickory, North Carolina, and has been doing so since 1978. Choose from stationary sofas, reclining sofas, and sectionals. The company offers an incredible selection of leather colors, and the frames are built from the highest-quality multi-ply wood components. Bradington-Young employs over 200 American workers and gives back to its community. Visit the website for finding your closest retailer.
BRIGHT is a New York-based brand that makes beautiful high-end sofas and other furniture for your living space. The company oversees all aspects of production, allowing for design flexibility. You’ll find classic, traditional, and contemporary styles in its selections, with most offered as modular seating. BRIGHT has been in business since 1927.
BuildASofa custom makes sofas in the USA at its Southern California facility. Shop online or at its Austin, Texas showroom. With over 10,000 custom orders under its belt, the company knows a thing or several about building sofas. Choose your style, fabric, and color, and within around eight weeks you’ll get the sofa or sectional of your dreams.
After experiencing their own struggles in buying a well-constructed sofa, the founders of Burrow created a then-new model for making, buying, and shipping well-made sofas in 2016. What you get is a high-quality couch that’s made in the USA from wood harvested in the south. You can have these sofas shipped for free, and you can even add extra seating to them later if you desire. Don’t let the easy assembly fool you: the attachment process is simple with these modular sofas.
Burton James defines casual elegance with its upholstered furniture made in California. The company designs and manufactures a range of sofas, sectionals, and more to exact specifications. It also is committed to sustainability while remaining uncompromising in its quality.
Carolina Chair makes its sofas, sleepers, and sectionals in Conover, North Carolina. The third-generation family-owned business uses local crafters to make each piece while allowing you to choose styles, fabrics, and even cushion options. Order directly from the company without needing to purchase from a local retailer. Carolina Chair offers free shipping to most states. Be sure to check its FAQs online.
Casara Modern designs and manufactures its midcentury modern style sofas in Huntington Beach, California. Some styles can be combined to make sectional arrangements. The company has a great selection of fabrics and remains true to the MCM design. Casara Modern offers free shipping and a five-year standard warranty.
Cisco Home is a furniture brand headquartered in Los Angeles and offers one made-in-the-USA sofa you can buy online: the Rebecca Deluxe Sofa in Denim White. I own a very similar sofa and love it! It’s constructed with a hardwood frame, has a foam core, and its cushions include feathers for you to sink into luxury. This company is the trifecta of a great company model: it practices sustainability, builds great furniture, and invests in people by teaching skills to the underprivileged and even donating spaces to local nonprofits. I’d say that’s a win-win-win!
Craftmaster has been making living room furniture since 1972 in Taylorsville, North Carolina. It offers over 800 fabric choices and over 50 leather choices. The company’s facilities are “EFEC” certified for best sustainable manufacturing practices, and its materials all have “Earthcare Inside” in order to reduce its environmental footprint. Craftmaster gives back to its community in numerous ways. It’s the exclusive producer of the Paula Deen Home Collection where this celebrity chef brings her warm personality into her living room designs.
Desiron is a luxury brand that makes modern furniture with premium materials in the USA. It uses sleek metals, luxury fabrics, and sturdy hardwoods. Desiron also practices sustainability in all its efforts, from reforestation to recycling and more. It has a New York Design Center showroom that features its most celebrated American-made furniture. The company makes the Hudson Sofa that’s available as a stationary or sleeper sofa.
Emblem’s sofas, sectionals, and other furniture are both designed and produced in California, and your order is shipped around three weeks after your order. The company uses recycled steel components, responsibly-harvested local wood, and chemical-free stains and glues to make its eco-conscious furniture. Choose from 12 different styles, including many European styles. Choose from Emblem’s own designs, or check out its customization options.
If you like log furniture, check out Fireside Lodge which makes its log sofas and other furniture in Minnesota. The sofa features bark-on hickory logs with a full log back and high-density foam cushions. Choose the upgraded fabric for longer and better durability. Fireside Lodge offers a limited lifetime warranty on manufacturer defects.
Floyd designs its products in Michigan and manufactures its sofas in the U.S. from nontoxic materials. Its sofas are crafted from cold-rolled steel and top-grade birch plywood. Originally made for apartment living, Floyd now offers sofas in several styles, and all its products are modular, made for disassembling and re-assembling. Note:Not everything Floyd makes is manufactured in the USA. Only its sofas are made on American soil.
Fusion Designs is located within Northern Indiana’s Amish community and was started by a local Amish crafter. The business has grown tremendously and offers a number of beautiful furniture products, including the Simplicity sofa. The bungalow mission-style sofa is made with hardwood including a walnut bowtie inlay on the arms. Add other matching pieces to the sofa for a completed look. Choose your fabric or leather as well as wood species.
Hammers and Heels, located in the Denver, Colorado area, takes reclaimed wood and makes gorgeous custom furniture. Each piece is handcrafted and made one at a time, using artistry methods and high-quality materials. The reclaimed wood is stained to a beautiful matching finish. Choose from several fabrics, including 100% linen. Hammers & Heels is a women-owned, designed, and led company.
If you need more glamour in your designs, check out Haute House Home. Designed and made in Hollywood, Haute House Home sofas, sectionals, loveseats, and other goods reflect the culture in which it is surrounded. Although you’ll love the look of the furniture reflecting Hollywood’s Golden Era, the actual manufacturing process takes between six and seven months to complete. If you want the look, the wait is well worth it! Choose from a huge variety of designs and fabrics. The company offers frequent online sales.
Located in Mt. Hope, Ohio, Homestead Furniture & Design looks like a storefront but also manufactures its own furniture by local Amish crafters. Not only that, but also the company strongly markets itself as a custom designer of furniture. Bring in your ideas, and they’ll build it! Choose from modern farmhouse, modern, midcentury modern styles, and more. Homestead Furniture & Design offers well-made sofas, sleepers, sectionals, and more for your home.
The Inside by Havenly brings several sofa options to the marketplace, all made in the USA—specifically in Pennsylvania, Illinois, and North Carolina. The company makes each piece when you order, which translates into less waste and better quality for you. Choose from the Classic, Modern, and Modern Sectional sofas. The Inside also lets you choose from 120 different fabric options (wow!). Receive The Inside’s “white glove delivery” and a one-year warranty on your purchase.
Inside Weather designs and makes its sofas, sectionals, loveseats, and other furniture in California. Choose from its original collection or its modular collection. I like that you can get sofas, accent chairs, and dining chairs in complementary styles and bright fabric colors. This sustainable company uses materials from upcycled water bottles while also planting two trees for every order placed. Inside Weather offers online sales, free swatches, and an amazing 365-day home trial.
Each sofa made by The Joinery is made in its Portland, Oregon woodshop and signed by the maker. These pieces are made both for homes and public places, so they’re built to last. Each sofa or loveseat is framed in hardwood responsibly harvested from the area, and the craftsmanship is impeccable. You’ll find midcentury designs, mission style, classic, and even modern selections that showcase gorgeous wood and comfortable cushions. Choose wood species and upholstery fabric.
How many cushions: 1, 2, or 3? Do you want a rounded or flat back? It seems that Kincaid offers just about any style of sofa you possibly could be looking for. The company has been making furniture in North Carolina since the 1940s, and they still use solid wood construction, English dovetails, and hand rubbed finishes. Choose from one of Kincaid’s designs, or custom design your own. Check the Kincaid website to locate a dealer near your home.
Lancer Furniture makes all its high-quality furniture in Star, North Carolina, employing local artisans in three different production facilities. The company has been making furniture, including sofas, sleepers, sectionals, and loveseats, since 1969. Buy pre-made or use the “Built for Me Series” to custom-make your sofa. Although Lancer doesn’t sell directly to the public, search its website to find retailers near where you live. Lancer Furniture offers a lifetime warranty on its products.
La-Z-Boy’s website says its furniture is “mostly” made in America. While I admit I’m not exactly sure what that means, I assume the company sources some of its materials offshore. It has production facilities in Tennessee, Missouri, and Arkansas, employing a total of 7,500 people. I love that La-Z-Boy markets its sofas based on your height, from sofas built for the petite person (that’s me!) all the way to someone extra tall (6’3” and up). While La-Z-Boy makes stationary and sleeper sofas, probably its most popular style is the power reclining sofa that combines the comfort of La-Z-Boy’s iconic recliners with three sculpted bucket seats. Adjust your headrest and leg rest with the touch of a button. You can also opt for built-in USB ports. La-Z-Boy sofas come with a limited lifetime warranty.
Maiden Home designs its products in New York and then employs artisans primarily from North Carolina to craft each piece using heritage techniques passed down through generations of makers. These are timeless pieces that you’ll find to be beautiful and comfortable. Shop sofas, sectionals, and other quality furniture pieces. Some selections ship in as little as two weeks.
Mantle Furniture, like many of our other listed brands, reflects the iconic quality and history of American-made furniture. For over 60 years, the Parker family has been handcrafting furniture in North Carolina and remains one of the few families still operating their own facility. The company painstakingly refines every detail in its sofas, loveseats, and sectionals (among other furniture selections, as well). Mantle Furniture products are made one at a time, and then the company ships your new furniture directly to you. Choose from ready-to-ship, or customize your selection. Choose from a 60-inch loveseat all the way up to a whopping 110-inch sofa!
Mayo Furniture was founded in 1965 and has been making furniture ever since. This family-owned business operates in East Texas and employs over 200 people in the making of sofas and other furniture. “Made in the USA” has always been part of the company’s mantra, and Mayo continues to buy American-made materials as much as possible. They strive to make furniture they would be proud to place inside their own homes. Shop for sofas and sectionals in over 300 fabrics, including leather and stain-resistant “revolution fabrics.” Search on the Mayo Furniture website to find a furniture retailer near you.
Based in Los Angeles, California, Medley Home handcrafts its fine sofas, sleeper sofas, and sectionals in the USA using fine quality eco-friendly materials. The company doesn’t use chemical-laden fire retardants on its furniture, an added plus when you shop for safe home furniture. You can tailor any piece to your own needs. Medley Home doesn’t have a store; instead, purchase online and save money by cutting out the middleman. Not sure about buying online? Medley Home offers a lifetime warranty, a 30-day in-home trial, and free returns.
If you want a designer sofa from a brand that celebrities like to talk about, check out Mitchell Gold + Bob Williams. You’ll find modern and contemporary sofas crafted in Taylorsville, North Carolina. These sofas combine luxurious designs, materials, and fabrics with everyday family living. This company and its artisans offer a lifetime warranty on its frames and cushions. Shop online where you’ll also learn about shipping costs and details on each product page.
Modernica makes its sofas and other furniture in California. Choose from either a walnut or steel frame and over five dozen fabric options to create a custom Scandinavian-style sofa you’ll enjoy for many years. For 30 years, Modernica has built each piece of furniture it offers in Los Angeles
Roger + Chris makes sofas that are pretty both inside and out. Its handmade frames are crafted from hardwood using hundred-year-old construction methods. These frames are guaranteed for life. Shop for just about any style and fabric, including leather and family friendly furniture. The sofas, sectionals, and sleepers are made in North Carolina. Skim the website to discover Roger + Chris feel like family more than a company. At the very least, you can challenge the owners to a game of Tetris!
Sabai makes sustainable sofas, loveseats, sectionals, and chairs in a family-owned North Carolina factory. Beauty and quality are Sabai hallmarks, and the company goes the extra mile to make chemical-free furniture. You can also read about Sabai’s efforts to reduce waste in its buy-back program. The company also helps you to trade in your Sabai furniture, repair it, or buy a secondhand one. It’s easy to order online, and your furniture ships flat in multiple packages. Get $50 off your first order.
Simplicity Sofas are handcrafted and custom built one piece at a time in High Point, North Carolina, using select grade solid oak lumber. 98% of the materials used come from American sources. The company offers 30 frame options that provide hundreds of combinations for sofas, sleepers, and sectionals, including smaller sofas ideal for apartments. Simplicity Sofas sells its products only through its website, cutting out the middleman. This enables you to buy a higher quality sofa for less money. The award-winning company offers a 10-year warranty on its products.
Smith Brothers Furniture of Berne, Indiana, has been around since the 1920s. The company employs 500 people in this small rural community. Hardwood maple, steel coil springs, highest quality foam, gorgeous textiles, and top grain leathers go into making the brand’s sofas, sectionals, and more. These truly are heirloom-quality, and I’m speaking from personal experience! Shop Smith Brothers’ styles or have the company custom make your own. Check the Smith Brothers Furniture website to find a local retailer, or visit its retail store in the small swiss destination town of Berne, Indiana.
Located in Oregon, Stanton has been making long-lasting sofas, sleepers, sectionals, and more in the USA for over 40 years. You’ll discover a number of sofa styles and fabric selections, including fabric that looks like linen but is stain-resistant. Frames are made with kiln-dried hardwood. Most retailers are located in the mountain states, or shop online at One King’s Lane, which has designed its own line of Stanton sofas.
Stuart David sofas and other furniture are made in California by third generation furniture makers. Its sofas and loveseats are more of a mission style with a modern flair. The wood used on the frames is sturdy hardwood; you can choose your specific species. Check out the Stuart David website, then shop at a fine furniture retailer near you.
Interested in other kinds of furniture made in the USA? Check out these articles!
Tammy Tilley is a southern transplant living in the Midwest. Growing up in the West Virginia hills, she was surrounded by family and friends who made things with their hands, from a penny whistle carved from the backyard tree’s branches to the hand-hewn wooden cradle gifted to her when her firstborn arrived. As an adult, she continues to be fascinated by the small cottage businesses the Amish and Mennonite communities cultivate in Northern Indiana. Tammy holds a B.A. and M.S. in English/Education.