THE FORGE
Every project we take on has a story. From unusual challenges to bespoke creations, we love sharing how we turn ideas into high-quality, functional and stylish metalwork. Explore some of our favourite builds and see the craftsmanship in action.
Behind the Build: Bespoke Stainless Steel Frame for Custom Cushion
26/09/2025
Project Overview:
Matt Hignett approached J.M. Metalcrafts with a unique challenge: a bespoke, oddly-shaped cushion designed to help wheelchair users improve personal hygiene and comfort, especially while on holiday in Portugal. He wanted a durable, high-quality piece that was both functional and visually impressive.
The Very First Sketch
When cushions get creative, sometimes all you need is a simple frame...
Further into the production there we other parts added in like frame supports and a handle.
The Challenge
The cushion’s unusual shape made measuring and designing the frame tricky, and stainless steel can be tricky to work with. Matt had a very specific vision that needed to be brought to life while staying within his budget.
Our Approach
We chose grade 304 stainless steel (TIG welded) to create a strong, polished framework. The frame was made using:
- Box section for the main structure
- Flat bar for support and fixing points
- Plate for secure attachments
- Tube for a smooth, comfortable handle
Throughout the process, we kept Matt updated with progress and offered expert advice, ensuring every detail met his expectations. Once completed, the frame was painted with a silver zinc galvanizing paint for a strong protective layer and a sleek finish.
Close-Up TIG Welds
Welded to perfection... or until the next coffee break!
You have to love seeing those colours on the welds, it is always satisfying.
Interested in a bespoke metalwork solution? Get in touch today to discuss your project!
The Result
The finished frame perfectly complemented the cushion, creating a sturdy, reliable, and stylish solution that Matt could take to Portugal for holidays and beach outings, making personal care much easier. The project successfully balanced functionality, durability, and budget considerations.
Client Feedback
Matt was thrilled with the final product (read his review). It was a pleasure working with such an enthusiastic, friendly and inspiring client. We’re proud to have been able to bring his idea to life and craft something that is going to improve comfort and independence.