Best Sofas

Sofas are a huge purchase, and a lot of the best materials going into them are coming from right here in the USA. Often times, large retailers will cut corners and construct their couches with cheaper materials from overseas. We did the research to find the American companies that are making the best sofas using U.S. materials in U.S. factories. Below are our findings, complete with our top recommendations and tons of details about each one, along with the factors that went into our research.

Our Findings

Overall, there are a ton of American manufacturers making sofas right here in the U.S. – we found over 20! Most of the prominent companies are located around the North Carolina area, which has historically been a big hub for furniture manufacturing. A big theme with our top picks is the ability to sell directly from the manufacturer to the consumer – doing so cuts out the retailer and allows manufacturers to reinvest those dollars (that the retailer would have gotten) into improving the quality of their product. We’ve split out each of our top picks into different style categories: slipcovered, customized, leather, sectional, loveseat, tufted, modern, and high-end couches. Read more about each of them below.

Top Recommendations

Best Sofas Best for:
Club Furniture Charleston Grand Sofa Slipcovered
Carolina Chair Fabric Variety
Roger + Chris Blythe English Sofa Leather
Simplicity Sofas Sectional
Club Furniture Barclay Fabric Upholstered Loveseat Loveseat
CoolSofa.com Manhattan Tufted Sofa Tufted
Modernica Split Rail Couch Modern
Mitchell Gold + Bob Williams Sloane Sofa High-End

Recommendations: Going Deeper

Check out additional details on each of our top picks, where they are from, what we liked about each one, and some of the things we didn’t like.

Best Slipcovered Sofa (and Most Affordable)

Club Furniture Charleston Grand Sofa


Handcrafted in North Carolina, the Charleston sofa from Club Furniture is as good as it gets when it comes to affordable slipcovered sofas. You can choose from around 100 different color swatches and the slipcover is completely removable if you want to switch up your style. We also love the comfort level – this couch is very deep with soft cushions (available in 2 or 3 cushions), but not too much sag. The springs, especially in the middle of the sofa, hold up well to 3 or 4 people sitting on the couch at a time. Club Furniture has great customer service as well, with completely free in-home delivery and set up and a 30-day in-home trial. Dimensions: W93″ x D40″ x H34″.

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Things we like:

  • No-sag springs
  • Several color options
  • Slipcover is easily removable
  • Low cost
  • Free delivery

Things we don’t like:

  • Slightly longer shipping times than we would like, around 4-6 weeks

Full lineup of slipcovered sofas: ClubFurniture.com

Best Sofa for Fabric Variety and Customization

Carolina Chair


Carolina Chair’s motto is “come straight to the source,” which is a spot-on description of this factory direct, family-owned sofa manufacturer based in Hickory, North Carolina. They have an impressive variety of fabrics and styles to choose from in their online store, and they even allow you to customize your order! Add or remove a skirt? No problem. Change up your cushion options? No sweat. We were really impressed by all of the different customization options that Carolina Chair has available, which is much easier for them to implement since they are not going through a retailer. Carolina Chair partners with Barrow Industries for their fabric options, which range from chenille, to denim, microfiber, suede, twill, and a ton more.

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Things we like:

  • Fabric selection
  • Ability to customize your sofa
  • Free shipping
  • Free in-home delivery

Things we don’t like:

  • Shipping times are rather long, around 6-8 weeks

 

Best Leather Sofa

Roger + Chris Blythe English Sofa


Roger and Chris are based in Omaha, Nebraska and are producing great furniture, everything from sofas to beds and lamps. Their Blythe English sofa really stood out among the competition for its amazing comfort level and traditional English roll-arm style, which fits well into a variety of home styles. The seat cushions are soft yet supportive, made from a foam core wrapped in channel-stitched down. The back pillows also feel really nice and are made from a split between feather and down. You can even customize your Blythe sofa a little bit! Roger and Chris offer a few customization options like different lengths, seat depths, and leather colors you can choose from. Sizes range from 38″ all the way up to 121″.

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Things we like:

  • Size options
  • Quality leather
  • Strong stitching
  • Very comfortable
  • Leg options

Things we don’t like:

  • Have to pay for shipping

 

Best Sectional Sofas

Simplicity Sofas


Another company selling direct from the manufacturer, Simplicity Sofas are custom built in High Point, North Carolina and they are making some of the best sectional sofas we found in our research. We spoke with Jeff Frank, President at Simplicity Sofas, who said their High Point location gives them several advantages. “Our High Point, NC location gives us access to quality materials and highly skilled craftspeople who know how to build high quality furniture the old fashioned way – one piece at a time.”

Each sectional unit is sold individually, so your whole couch can be customized as you like it, and it has the added benefit of being able to fit through pretty much any doorway or stairwell. The frame for each section is made from solid oak, so we found the support to be very sturdy (selling to customers straight from their factory and not going through a retailer allows them to invest more in the construction of their sofas). The sectionals are very easy to put together as well and don’t require any tools.

In terms of style variety, Simplicity Sofas offers over 300 fabric and leather variations. When you choose the sectionals you want, you can customize the fabric, foot style, cushion style, cushion type, and select among a few different add-ons as well. Frank is excited about their trends in fabric sourcing: “One of the most encouraging trends in the furniture industry right now is the return of American fabric manufacturers. Ten years ago, almost all of the fabrics we used were imported. Today 75% of our customers are choosing American Made High Performance fabrics.”

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Things we like:

  • Ability to customize
  • Easy to construct
  • Fabric variety (free swatches available)
  • Sturdy frame
  • Very comfortable

Things we don’t like:

  • Free shipping for most, but a $100 surcharge is applied to shipments out west to: California, Oregon, Washington, Idaho, Arizona, New Mexico, Utah, Nevada, Wyoming, Montana and Colorado

 

Best Loveseat

Club Furniture Barclay Fabric Upholstered Loveseat


When we looked for loveseats, we were pleasantly surprised to see Club Furniture at the top of our analysis again. Their Barclay loveseat is comfy, affordable, and comes with some customization options for fabric and legs. This loveseat is perfect for a smaller room or apartment at 60″ wide, 38.5″ deep, and 36″ in height. We found the cushions to be very comfortable with an appropriate amount of “sag” to them. Fabric options range from microfiber velvet, to twill, canvas, chenille, and a few more styles. As with the rest of their products, Club Furniture will deliver this piece to your home free of charge and give you a 30-day in-home trial if you want it.

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Things we like:

  • Large selection of fabrics
  • Very comfortable
  • Minimal sag
  • Affordable
  • Free delivery

Things we don’t like:

  • Shipping times are a little long, around 4-6 weeks

 

Best Tufted Sofa

CoolSofa.com Manhattan Tufted Sofa


CoolSofa.com makes all of their custom sofas in Santa Ana, California, including this Manhattan style, which is the best tufted sofa among the ones we could find. We love the iconic Chesterfield design and attention to detail within the style of this couch – the tufting is very well stitched and it’s accented with a polished nail head trim that really makes this sofa stand out. The wood frame is also very solid. The Manhattan comes in a few different fabric styles (white leather shown here), like textured, microsuede, velvet, and even animal prints. You can add a matching ottoman and some throw pillows as well if you’d like. Dimensions: W92″ x D34″ x H35″.

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Things we like:

  • Well stitched tufted style
  • Sturdy frame
  • Fabric options
  • Depth

Things we don’t like:

  • Have to pay for shipping

 

Best Modern Sofa

Modernica Split Rail Couch


The Modernica Split Rail Couch is handcrafted in California and an awesome, modern style to have in your home or office. Each of these couches are made to order based on your specifications, with 30 different fabric choices and a couple of options for your frame, either a North American walnut frame or a triple chrome-plated steel frame. We really like the sharp angles of the couch and the lack of armrests that help create the modern, minimalist look. The exposed frame is also unique, fully showing the legs and the back of the couch. Dimensions: H38″ x W88″ x D42″.

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Things we like:

  • Exposed frame
  • Fabric options
  • Sharp edges
  • Comfortable

Things we don’t like:

  • Typically ships in 6-8 weeks

 

Best High-End Sofa

Mitchell Gold + Bob Williams Sloane Sofa


The Sloane Sofa is made with incredible craftsmanship, and it shows in the price tag. It’s inspired by mid-century Danish styles with a sharp profile and tapered legs. The Sloane is a little more shallow than your typical sofas of similar size, which makes it easier to get in and out of, but less ideal if you really want to “sink” into your couch. This sofa has a very tight and supportive back too. These guys let you customize your sofa how you want it, with over 300 fabric and finish options. In addition to fabric and color, you can choose from a bunch of options for: leg finishes, cushion fill, base cover, contrast cushion, and contrast welt. We also liked that the Sloane Sofa comes in a couple of different lengths, 74″ and 84″.

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Things we like:

  • Customization
  • Back support
  • Shallow depth
  • Fabric choices

Things we don’t like:

  • Long shipping times, around 8 weeks

Recap: Best Sofas Made in the USA


Factors We Considered

Comfort

Comfort is a non-negotiable when shopping for a couch. We looked for sofas that are made from the best materials and have good support with the inner springs in the cushions. Feel the springs inside the sofa – they should be tight and close together. In terms of filling, there are a couple of things to look out for. High-resilient (HR) foam is slightly more expensive, but worth it for the durability and comfort level. Polyurethane foam is cheap and typically less comfortable.

Style

Every person’s style is different. We made sure to choose a variety of sofa styles to cover a wide variety of interests. Many of our top picks have several hundred fabric and color options.

Durability

A sofa is a lifetime investment, so you need to make sure that it can last reliably year after year. There are a few different factors to look for when it comes to durability: the frame, fabric, joinery, springs, and fillings.

The frame is ideally made of a hardwood like oak or beech. Soft woods like pine can warp pretty easily over time.

We looked for fabric options that are tough for everyday use. After all, you never know what is going to spill on it. Synthetic microfiber, leather, and fabrics with patterns woven in (rather than printed) are all winners.

The joints of your couch should be solidly constructed. Avoid couches held together by nails and glue, and opt for ones that wooden dowels or corner blocks.

As mentioned before, springs in the couch should be firm and close together.

Fillings like high-resilient foam are good, polyurethane foam is bad. See more above.

Ability to Customize

As a staple of your home, a sofa is a very personal purchase. So, the ability to customize is important. Often times, manufacturers have several options for each piece of the sofa on hand, and are willing to create a custom order (often times for a slightly higher price). We made sure to include some sofa manufacturers that have good custom options.

Customer Service

Customer service is so important for such a big item like a sofa. We looked for manufacturers who are offering lifetime warranties, free delivery, setup services, a responsive customer service team, and more.

Value

We want to make sure you are getting the best sofa for your money. We eliminated several brands where we felt like the quality of the couch did not live up to the price on the tag. After all, we’re consumers too!