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From Sofas to Hospital Gowns: How Our Partners are Stepping Up

“Look for the helpers,” was Fred Rogers’ wise advice for children in times of crisis. “Be the helpers” is the reality playing out at several of our major furniture partners during the COVID-19 pandemic—and we’ve never been prouder to know them.

Women in warehouse smiling and waving

Character beyond craft. In the rolling foothills of Hickory, North Carolina at Design Foundry—our partner factory where our Gather, Peyton and Hayward sofa collections are made—the company’s founder, Eric Fulcher, says he feels “honored” and a “huge sense of pride” that his team of 75 workers has been able to quickly shift 25 percent of its operations to the manufacture of hospital gowns.

It wasn’t simple. First, Design Foundry needed to get its hands on the right kind of fabric—and a lot of it. For that they turned to an organization called Carolina Textile District (501c3) in Morganton, NC, that connects local textile artisans with partnerships and sourcing opportunities. The Catawba County Economic Development Corp. made the introduction, and is working with Design Foundry to distribute the items to state-run hospitals, first responders, nursing homes and other medical facilities.

Next came production logistics. “We are an upholstery manufacturer,” says Fulcher, “Sewing a sofa cover is a very complex and different process compared with sewing a hospital gown with simple seams and straight lines.” A dedicated team of five fabric cutters and 25 sewing technicians is now working solely on the gowns, with the entire factory pitching in to help label, fold, pack, box and ship them.

The shift to making PPE (personal protective equipment) has helped Design Foundry avoid the layoffs that have already affected so many furniture businesses in the region. “With retail stores closed across the country, orders started to drop off dramatically,” says Fulcher. “Many of our associates have a spouse who is out of work and fearing for their job when all of this is over. We’ve been able to keep folks working by using our craft to make much-needed medical supplies while still filling our orders for Crate and Barrel.”

Since opening in 2018, Design Foundry has made giving back—in both volunteer hours and dollars—a big part of its “why,” Fulcher says. Making PPE during a national crisis feels like a natural fit for a company so focused on community. “Knowing that we have an opportunity to help those on the front lines providing healthcare to people who are sick and struggling to live—again, we are extremely honored to be able to serve in this way.”

Warehouse employees posing for photo surrounding three couches

More of Our Vendors Now Making PPE

  • American Leather, Dallas,
  • and LEE Industries, Conover, North Carolina
  • Face Masks and Hospital Gowns

A Crate and Barrel vendor for more than 20 years, LEE Industries (owned by American Leather, another of our vendors) is currently closed for upholstery production, but associates have the option of helping to produce thousands of masks and gowns per week to support local hospitals and organizations in need in Texas and North Carolina.

  • McCreary Modern, Newton, North Carolina
  • Face Masks

McCreary Modern, a Crate and Barrel vendor for 30 years, has been producing FFP2 Class II Surgical Mask for over 4 weeks, and distributing to local nonprofits and first responders (Caldwell County Emergency Medical Services, Lenoir Fire department, various regional volunteer fire departments and municipalities) and healthcare providers ( UNC Healthcare), Catawba Regional Medical Center, assisted living) in the immediate area. So far McCreary Modern has distributed over 40,000 masks. McCreary Modern is providing these at NO COST to the agencies and operations that have requested assistance. They are using paid McCreary Modern employee-owners volunteers to cut and sew the mask and are absorbing the cost of labor and materials.

  • Steele Canvas, Chelsea, Massachusetts
  • Face Masks

Steele Canvas, a Crate and Barrel vendor since 2012, is producing and donating face masks to hospitals and healthcare workers in need. Steele is also offering masks for sale to customers as part of a buy one, give one donation opportunity.

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