Upholstery Pattern Maker

Position Summary:

We are seeking a hands-on and technically skilled Upholstery Pattern Maker to support the end-to-end development of upholstered furniture products. As a key member of the Product Development team, you will create precise upholstery patterns and ensure a seamless transition from prototyping to production.
This role requires expertise in pattern development, upholstery construction, and close collaboration with cross-functional teams, including Product Engineering, Manufacturing, and Design. Strong experience in patternmaking, upholstery fabrication, and Design for Manufacture (DFM) principles is essential for success.

Responsibilities and Essential Functions:

Product Development Execution

• Develop highly accurate and production-ready upholstery patterns that meet structural and aesthetic requirements, compatible with various foam substrates.
• Translate design concepts and CAD models into physical and digital patterns that achieve smooth, wrinkle-free finishes and precise seam alignment.
• Collaborate with Product Engineers and Designers to provide expert feedback on foam shapes and densities, improving visual consistency, ergonomic performance, and manufacturing efficiency.
• Lead prototype builds, including complex foam applications such as integrated molded foam parts and over-molded frames, ensuring patterns align with foam compression zones and critical tolerances.
• Troubleshoot and resolve pattern-related challenges such as foam deformation, seam strain, and fabric tension to support seamless production scaling.
• Create and maintain technical documentation for all patterns, including material requirements, upholstery pull strategies, and alignment details.
• Define and uphold pattern standards and quality benchmarks across projects.
• Work closely with manufacturing teams to ensure repeatable, high-quality production outcomes.
• Partner with Supply Chain, Production, Design, and Engineering teams to execute efficient, on-time product launches

Design for Manufacture (DFM) Support

• Apply DFM best practices to assess construction methods, and production feasibility ensure timely feedback to the Product Engineering team.
• Apply DFM principles to foam-based upholstery patterning by evaluating foam parting lines, density zoning, and optimal seam locations to facilitate efficient assembly and improved visual quality.
• Recommend adjustments to foam tooling or construction—such as adding reliefs, chamfers, or anchor points—that enhance fabric laydown or reduce variability in upholstery pull.
• Work with engineering and factory teams to refine patterns that interact with multi-density or over molded foam designs.
• Identify and recommend cost optimization opportunities while maintaining product quality and design aesthetics.
• As needed, train the production teams on NPI to ensure seamless integration.

Digital Tools

• Digital patterning, nesting, grading, and integration with automated cutting.
• Experience in using digital tools for flattening complex 3D upholstery surfaces into precise 2D patterns.
• PLM/PDM Systems, for managing BOMs, revisions, and technical documents.

Physical Tools & Equipment

• Proficient in industrial sewing machines, upholstery cutting tools, rotary cutters, and measurement equipment.
• Hands-on expertise with foam, muslin, vinyl, and other prototyping materials.
   

Qualifications, Skills and Education:

Required Qualifications:

• Patternmaking or equivalent technical certification.
• 5 + years of hands-on experience in upholstery pattern making and fabrication, including projects using cut foam, molded foam, and over molded substrates.
• Demonstrated ability to pattern for complex foam assemblies and provide feedback on foam form to enhance upholstery quality and consistency.
• Ability to analyze foam-behavioral characteristics (e.g., spring-back, compression, adhesion) and integrate them into upholstery pattern decisions.
• Proficiency in upholstery tools, industrial sewing machines, and prototyping equipment.
• Proficient in Optitex, Gerber AccuMark, Lectra, ExactFlat or other patternmaking software.
• Strong written and verbal communication skills; ability to clearly articulate technical concepts.
• Experience with developing upholstered products from concept through production launch.
• Ability to interpret sketches, CAD Drawings and 3D models into physical patterns.

Preferred

• Experience working with U.S. based consumer product companies and cross-cultural teams.
• 3D software experience (CLO, Browzwear) for digital patterning and visualization.
• Experience using Industrial sewing machines; Juki, Pfaff, Consew 
• Experience with North American manufacturing and rapid prototyping workflows.
• Knowledge of upholstery across diverse applications (residential, commercial, automotive).
• Spanish/English bilingual is an asset.

Physical Demands

• Ability to stand for extended periods while working on pattern layouts.
• Manual handling of upholstery fabrics, leather, and tools.