Abstract: Furniture, such as a chair, and method of assembly thereof includes the steps of configuring an upholstery fabric outer covering and a flap having one or more open sides, the flap affixable on one side to the outer covering. A number of foam blocks are configured in shapes, which, taken together, conform to the shape of the furniture to be assembled.

Abstract: A support system including polyurethane layers having different indentation load deflection characteristics and a plurality of zones to vary the level of support in different regions of a reclining or sitting body.

Abstract: A chair and method of assembly thereof includes the steps of configuring an upholstery fabric outer covering and a flap having one or more open sides, the flap affixed on one side to the outer covering the flap further having means for attaching the open sides of the flap to the outer covering. A number of foam blocks are configured in shapes, which, taken together, conform to the shape of the chair to be assembled. Finally, the foam blocks are disposed within the outer covering so that the blocks completely fill the outer covering and cause it to assume the form of the chair, with the final product having a robust structure without the use of other structural components.