Ever wonder how soft seating is made? Soft seating is an essential tool for creating dynamic, diverse learning environments where students can Thrive. Read more about our Thrive Philosophy and how it impacts our product designs. 

MooreCo proudly manufactures all its soft seating in the USA. MooreCo incorporated CJ Designs into the MooreCo family in 2023 to continue our commitment of manufacturing exceptional products. Take a look inside our facility to watch the process from start to finish! 

All Foam Soft Seating Made in the United States

The acquisition of CJ Designs allows our Thrive Philosophy to be implemented across all product solutions more holistically, enabling us to imagine new and reliable products to meet the developmental needs of all students. 

All Foam Soft Seating is the newest addition to our inclusive, versatile, adaptable line of products. Presented in three collections, all foam soft seating is not just about comfort and playfulness, it’s about creating an environment that meets each student where they are developmentally and help them discover their ideal position for learning. 

This blog outlines how we manufacture our newest line of All Foam Soft Seating and how to maintain the collection to keep it looking great for years to come!

What is All Foam Soft Seating?

All foam soft seating is sturdy, lightweight, soft seating manufactured entirely or primarily form high-density foam. Some of the MooreCo shapes come with a plywood bottom for more structure. The foam is covered in soft, durable fabrics that resist wear and tear for years. 

Soft seating made entirely of foam is comfortable, easy to move, and adds exceptional flexibility to classrooms, libraries, media centers, common areas, and more. They come in a variety of shapes, sizes, and heights enabling each student to find a seat where they feel most comfortable physically, mentally, and emotionally.

The shapes are specifically designed to encourage students to move their bodies and experiment with different seating positions. They can sit upright, cross-legged, lay down on their backs or stomaches, or lounge. Students can easily move the lightweight pieces around their learning spaces to create collaborative groups, socialize, or create a private learning space. 

The exceptional durability and flexibility of all foam soft seating makes it an essential additional to any 21st-century learning environment. 

How is All Foam Soft Seating Made?

MooreCo's All Foam Soft Seating is made with top-quality, high-density, anti-microbial foam that meets all TB 117-2013 guideline and durable, easy-to-clean fabrics. Our products are SCS Indoor Advantage Gold Certified and come assembled with breakaway safety zippers and GREENGUARD certified, flame resistant upholstery.

To start the process, we bring large buns of foam (108” x 82” x 36” thick) into our manufacturing plant in Tennessee.  We first create foam slabs on our foam slitting machine based on the thickness needed to create the piece.  After the slab is created, it is moved to our CNC wire cutting machine where individual foam shapes are nested and then cut. 

Select ottomans with wooden bases from the Tinker collection are made of top-quality, high-density foam adhered to a E1/EPA TSCA Title VI/CARB phase 2 compliant plywood bottom with solvent-free Simalfa water-based adhesive and finished with glides or aluminum legs.

The finished shape is then covered in a durable fabric and closed with a zipper.  Once the fabric is pulled over the shape and zipped up, the zipper tab is removed so that the fabric can not be removed by eager, exploratory learners. 

The product is now complete and can be shipped to its new home! 

All the waste foam from these operations are either shredded for use as bean bag filler or baled for sale to companies who use the waste to create other foams for carpet padding or floor pads.

Maintenance Tips for Keeping All Foam Soft Seating Clean and Durable

MooreCo's all foam soft seating is made of densely woven, high-quality, durable fabrics. Simply wipe with water-based foam or cleaner for easy maintenance. For more information regarding Momentum fabrics, visit their website. 

Help MooreCo help you  create a welcoming, comfortable atmosphere, encourage community and cooperation, improve the emotional well-being of your students, and increase focus, productivity, and positivity with our three new lines of All Foam Soft Seating. 

MooreCo's Sustainability Promise

Sustainability and social responsibility are more than buzzwords at MooreCo—they are guiding principles for long-term growth, civic consciousness, and global awareness. Being a global company comes with the responsibility of being a good global citizen. MooreCo is dedicated to conducting business with integrity to pursue growth that improves customer experience, benefits our employees, meets ethical standards, and protects the environment.

We’ve integrated numerous sustainability initiative into our operations, including:

• Designing and producing environmentally friendly products, and seeking certification via such organizations as SCS Global Services
• Specifying recycled content in our purchased component parts
• Establishing recycling programs in our manufacturing facilities and office for corrugated steel, aluminum, paper, and plastics
• Using soy/vegetable-based inks and FSC paper for printed materials
• Reviewing ground transportation routing to conserve gas and reduce emissions
• Using technology to reduce paper and mail volume internally and externally
• Encouraging telecommuting and carpooling, as well as telephone and web conferencing options to reduce travel
• Using greener office supplies as well as products, such as paper towels and bathroom tissue, that are made from post-consumer materials
• Processing scrap styrofoam and polyurethane for fill materials in our bean bag products
• Baling and selling excess polyurethane foam to be remanufactured into other foam products such as carpet padding and floor mats
• Baling and selling scrap cardboard for reprocessing into liner board for packaging materials
• Donating excess fabric and wood materials to local schools and daycare centers for use in arts and crafts
• Collecting all paper, plastic, and aluminum waste for recycling through local services
• Using solvent-free, GREENGUARD Gold Certified Simalfa® water-based adhesives to bond our foam to wood frames
• Using plywood that is E1 / EPA TCA Title IV / CARB Phase 2 compliant
• Using only hardwood that is provided from reforested sources
• Using upholstery foams that are highest quality, meet TB 117-2013 standards, and contain no added fire-retardant materials
• Using only packaging materials that contain at least 25% recycled content