Every cut, every stitch, every seam by hand.
Plush + Oak was founded with a clear vision. To bring to market, luxury salon and spa furniture that was highly customizable, and to produce quality and comfort that had never been seen before in the professional furniture market. It was clear from the beginning that mass producing our items or outsourcing manufacturing to overseas wouldn't be an option for the company. The only way to ensure excellence was an in-house manufacturing team, who would be passionately dedicated to ensuring that the quality of our pieces exceeded the expectations of our customers.
Today the Plush + Oak manufacturing team has produced over 6000 made-to-order spa beds by hand and has grown from six, to seventeen highly skilled journeyman craftsman and women with a combined 277 years of upholstery experience between them.
Materials drive durability.
Plush + Oak is committed to exceptional quality through every aspect of our furniture, and this begins with the materials used to construct our products. As a company value, we use materials sourced and made in North America as they are stronger, longer lasting, and better quality than imported furniture materials - the one exception to this is our electric components which are manufactured in Europe and imported to our facility.
The reason Plush + Oak beds feel so different than what's on the market is because, they are. From our kiln dried hardwood framing with steel reinfrcements, to our tensile woven suspension system installation that gives a sofa like "sink in" feeling, to our layering of multiple foam densities in every bed to add weightless "squish" (memory foam), exceptional rebound (Ro8), or structure and durability (Hi-LOFT™) applied and layered for performance and comfort.
The Manufacturing Journey
Step 1: Framing
The foundation of every Plush + Oak bed begins with our kiln-dried hardwood frames, meticulously crafted for strength and longevity. Using state-of-the-art CNC cutting technology, we ensure absolute precision in the curvature and dimensions of each frame, maintaining consistency across every piece. Once cut, our journeyman carpenters expertly assemble the frames, reinforcing them with strategically placed steel brackets and bracing for unmatched durability and structural integrity. This careful construction process ensures a solid, long-lasting foundation that upholds the highest standards of craftsmanship and quality.
Step 2: Suspension
With the hardwood frame expertly assembled, we move on to one of the most crucial elements of Plush + Oak beds—the suspension system. Using high-quality elasticized upholstery webbing, our craftsmen meticulously secure each strip to the frame, creating a strong yet flexible foundation. This webbing is strategically tensioned—pulled tighter in areas requiring firm support and left slightly looser in others to enhance comfort—ensuring the perfect balance of structure and plushness.
Plush + Oak suspension systems are designed to mimic the luxurious, sink-in feel of a high-end sofa. This unique suspension system provides exceptional comfort while maintaining durability and longevity. Once installed, each bed undergoes a thorough tension test to verify that the webbing is evenly balanced, securely fastened, and ready for foaming.
Step 3: Foam Layering
Comfort and durability come together in this critical step, where each Plush + Oak bed is carefully layered with a combination of high-quality foams. Every bed incorporates a minimum of two different foam types, strategically placed to serve specific functions, ensuring both a luxurious feel and long-term resilience.
At the topmost layer, where the client rests, we use plush memory foam to create a soft, contouring surface that provides the signature "squishy" sink-in sensation. Beneath this, we incorporate RO8 luxury rebound foam, a high-end material designed to quickly regain its shape once weight is removed, adding longevity and maintaining the structural integrity of the bed over time. Finally, Hi-LOFT structural foam is applied to reinforce the body of the bed, enhancing density and shape retention to ensure a well-supported foundation.
Each foam layer is meticulously positioned based on where it provides the most benefit, carefully balancing softness, support, and durability. This thoughtful layering process is what makes Plush + Oak beds not only incredibly comfortable but also built to withstand years of use without losing their premium feel.
Step 4: Sewing
Our seamstress team hand-cuts every flute, pillow, and panel with meticulous detail. Using time-honored techniques, they sew each cover and panel in a variety of elegant, timeless stitching styles.
From piping and french seams to box pleats and custom detailing, every stitch is carefully executed to enhance both the durability and aesthetics of your bed. The material and shade of your choice —is expertly tailored in the exact shade you’ve selected, ensuring a flawless, refined finish.
This artisanal approach to sewing not only elevates the beauty of each Plush + Oak bed but also guarantees long-lasting quality that withstands the test of time.
Step 5: Upsolstery & Assembly
In this step, our journeyman upholsterers bring every element together, transforming individual components into a beautifully finished Plush + Oak bed. With expert craftsmanship, they carefully stretch and secure the meticulously sewn fabric covers over the layered foam and precision-built frame, ensuring a seamless, tailored fit.
Each curve, seam, and panel is smoothed and aligned to perfection, with attention to detail that ensures both durability and elegance. Our upholsterers work with precision, ensuring that the fabric lays flawlessly, the stitching remains crisp, and every contour is sculpted to Plush + Oak’s exacting standards.
This final touch is what gives our beds their refined, luxurious aesthetic and unmatched comfort—crafted not just for function but as a statement piece that enhances any salon or spa environment.
Inspection and Packing
The final step in our production process is our rigorous 18-point inspection, designed to ensure every Plush + Oak bed meets our exacting standards of quality, durability, and aesthetic perfection. Our expert team meticulously examines each bed from every angle, checking for structural integrity, flawless upholstery, and precision in every detail. This 360-degree inspection guarantees that your bed arrives in pristine condition, ready to provide unmatched comfort and support. Once a bed successfully passes this comprehensive quality check, it is carefully packed in secure, reinforced packaging to protect it during transit. From our workshop to your door, we take every precaution to ensure your bed arrives safely and in perfect condition, ready to elevate your space.
