Every furniture frame made by Campio Furniture is composed of 80-100% of hardwood to ensure superior durability. The hardwood is kiln-dried, milled and processed to remove any defects that may lead to structural weakness.

There are many reason why kiln-dried wood is essential in the manufacturing of quality furniture.

It removes excess sap and moisture, which can cause frames to warp.

It prevents the wood from absorbing any moisture in the future. Moisture absorption can cause the frame to swell, shrink or change shape, and loosen the joints and fastenings.

Kiln-drying is also the ideal for ensuring long-term stability and shape retention for the life of the furniture.

For added stability and structural support, the frames are corner blocked, power nailed, screwed and glued.

The design of the frames is engineered according to industry standards, which take into account seating pitch, depth and height. This ensures style won’t compromise proper construction.

All frames are then padded with foam or polyester Dacron to ensure that the leather is not damaged due to contact and friction against the frame.

To eliminate sagging in the seats and backs, a sinuous spring system is used.

The 8-gauge springs on the seat and 11.5 gauge springs on the back are cross-wired for added support and stability.

Nylon coated clips are used to fasten the springs. This prevents squeaking and minimizes noise during the spring’s use.

The springs are further protected and insulated by quarter-inch sisal, in addition to a layer of decking. The decking also any damage by ensuring that the springs are not in direct contact with any other components of the furniture.

Campio Furniture uses a high-density polyester Dacron foam in its seat construction, resulting in greater shape retention and long-term durability.

By using Dacron foam with a density higher than the industry standard, Campio Furniture is able to create furniture that has a softer feel, and which moulds perfectly to the user’s contours.

For the back rests, Campio Furniture uses a polyester blow-fill for added durability, comfort and softness.

Some styles, however, do not have back pillows. These styles are referred to as "tight-back" or “semi-attached back”.

Campio Furniture uses both traditional and modern techniques for cutting the leather used in its furniture.

In both approaches, an employee first scans the leather for defects or flaws. The pattern is then placed around any such defects.

Using the traditional technique, the leather is either cut by hand or a die-cast machine. This approach, however, can be quite labour intensive.

For greater cutting efficiency, Campio Furniture uses a sophisticated, high-pressure water jet cutter.

This innovative technology follows similar cutting procedures as cutting by hand, only every step is automated by computer, thereby saving both time and resources.

On average it takes approximately 2 minutes for a hide of leather to be cut with this new technology, a vast improvement over cutting by hand or die cast machine.

There are three main types of stitches used to sew the pieces of leather together. These are, Regular Stitch, Top Stitch and Baseball Stitch

The type of stitch used depends on the style of the furniture being created.

Each piece is sewn by a qualified operator to ensure proper fit and alignment of each piece. A minimum of 5 stitches per inch is required to ensure durability of the seam.

Leather is the covering of choice for Campio Furniture’s leading furniture suites due to its visual appeal and durability. Leather will not tear, is difficult to puncture, and typically outlasts synthetic materials 4 to 1.

Leather can come from a variety of animals, however, the best and most widely-used leather for the furniture industry comes from cows.

Cowhide is generally softer to the touch than other cheaper leathers.

Leather is categorized in terms of the grain type. These are split grain, top grain and full grain.

Split grain leather is the lower layer of the hide and is characterized by fibres that run in the same direction. As a result, split grain has less strength and durability than top grain.

Split-grain leather is still considered “all leather” or “genuine” even though it is of a slightly lower quality than full grain or top grain leathers. Split grain is typically cut away in order to acquire the top-grain.

Furniture suites sold by Leon’s feature Campio Furniture’s top grain leather. Top grain leather is the strongest and most durable part of the hide. The durability comes from the inconsistent fibre patterns, which prevent the hide from tearing.

Full grain leather, meanwhile, is essentially top grain leather that has not been buffed or corrected. As a result, full grain retains the natural scratches and scuffs of the hide for a unique look.

Both split grain and top grain leathers can be corrected, that is, buffed or sanded to remove imperfections in the grain. Full grain leather, on the other hand, is never corrected.

Colouring leather can be achieved in a variety of ways, including pigment dyes, semi-aniline dyes and aniline dyes.

A pigment dye is a protective opaque colour applied to the surface of the leather. Although being extremely durable and stain resistant, it is less pliable, soft and slightly cooler to the touch than semi-aniline and aniline dyed leathers.

Semi-aniline dyes combine aniline dyes with pigment dyes to enhance uniformity in colour and soil resistance, while remaining soft, pliable and warmer to the touch.

Campio Furniture uses aniline dyes on most of its leather furniture suites.

It should be noted that all leather will have a tendency to fade if exposed to direct sunlight for long periods of time, or if one area of the furniture is used significantly more than other areas.

In addition, darker colours tend to hide dirt and soil better than lighter colours.