When The Hastings Sofa Company recognised a need to modernise its manufacturing processes, it turned to cutting-edge technology provider Vetigraph for the solution …
The Hastings Sofa Company is a British designer and manufacturer of premium-quality sofas and upholstery products, specialising in bespoke and white-label furniture for leading retail brands and high-end clients. With a background in furniture design and production, operations director Marc Gall works alongside Danny Cleaver (MD) and Mark Hillyard (FD) to drive the business forward.
While the company’s craftsmanship was never in question, its production methods were rooted in manual processes. Creating physical patterns and hand-cutting fabric was labour-intensive and prone to inconsistencies. This traditional approach led to significant material waste and slower production times, creating a major obstacle to ambitions for growth and scalability in a competitive market.
To remain agile and efficient, The Hastings Sofa Company needed a solution that would streamline its operations without compromising the rich heritage of craftmanship and high-quality furniture it was known for – and the decision was made to partner with Vetigraph and implement a comprehensive solution, including a CNC automatic fabric cutter and advanced CAD/CAM software.
“The transition from manual to digital was seamless, thanks to Vetigraph's expert support and tailored on-site training for the team” explains Marc. “The team quickly moved from physical patterns to precise digital models, immediately transforming the cutting room.
“The impact of the new system was immediate and profound. The CNC fabric cutter drastically reduced cutting times, while the software’s intelligent marker-making features optimised fabric layouts to a degree impossible by hand. This innovation significantly reduced material waste, directly lowering costs, especially on our most premium and expensive fabrics.”
With digital patterns, every cut is now perfectly consistent, says Marc. This eliminates errors and inconsistencies, ensuring every sofa component fits flawlessly.
“The enhanced precision and speed allows the business to handle larger, more complex white-label and bespoke orders with confidence,” he adds. “We can meet tight deadlines for major retail partners without sacrificing our high standards.”
The Vetigraph solution did not just improve one process – it transformed the company’s entire operation. By enabling faster production, greater cost efficiency, and “unwavering” product quality, it empowered the business to scale its capacity and cement its position in the UK's premium furniture market.
As the furniture industry faces various challenges, including supply chain pressures and the demand for sustainability, The Hastings Sofa Company is well positioned for growth. With plans for expanding white-label partnerships and innovating new products such as sofabeds, the company’s commitment to quality, efficiency and strong customer relationships remains unwavering, reinforced by Vetigraph’s expertise.
