The Zipline Love Seat Jr gives hours of comfort and entertainment to any playroom. The love seat provides plenty of space for two little butts, plus a little bit of room to keep the cooties at bay. Remove the ottomans for use as building blocks, or nest them in the love seat and unfold the unit to create a crash pad or play mat.

The Zipline Love Seat Jr gives hours of comfort and entertainment to any playroom. The love seat provides plenty of space for two little butts, plus a little bit of room to keep the cooties at bay. Remove the ottomans for use as building blocks, or nest them in the love seat and unfold the unit to create a crash pad or play mat.

The Zipline Love Seat  Jr folds out into a play surface. It's soft enough to prioritize safety, yet sturdy enough to keep that train set intact.

Place one of the ottomans in the seating area to transform the Love Sea Jr into a work surface.

The polyurethane foam filling we use is perfect for compression packaging. We can fit 50-75% more product on a shipping pallet—cutting shipping costs by nearly 50% and reducing our carbon footprint.

Caterpillar Pods offer a simple solution for collaborative seating with a modular building block approach. The combinations of designs and arrangements are endless, making Caterpillar pods ideal for classrooms where work space is constantly transforming. Stack the pods vertically for storage when they’re not in use.

For a kid, there’s nothing like building your own playground. With Jaxx® Shapes, children can express their creativity through constructing (and demolishing) their own customized playscapes. These shapes are lightweight, soft, and easy to maneuver, transforming any early learner into an architect-in-training.

Jaxx ® Shapes are lightweight and easy to maneuver. Young children can move the shapes around however they'd like, giving them full control over their creations.

Whenever my teammate’s daughter would come to the office, she would always want to play with whatever pieces of foam we had hanging around. The creativity she showed with such simple shapes got us thinking: could Jaxx create a solid foam product line for children?

We created a series of concept sketches and quickly translated them into small models. This is a very quick and easy way to expand our thinking as we develop new ideas.

We often work with a concept at 1:4 scale so that we can quickly test ideas with less waste. 

Full-size samples help us understand the scale of each concept and refine some of the ideas we’ve developed through small-scale models.

Once we’ve proved the concepts in full-scale, my team runs cost scenarios on the designs to weigh price and value. We optimize our fabric-cutting using CNC routing software, Lectra Diamino, to make sure we achieve the highest efficiency possible. 

This automated Lectra Q25 machine cuts along our fabric pattern markers using an oscillating razor blade and a vacuum table. This machine can save a lot of time and labor, but only if it's optimized for each new product. To do this, we develop detailed training instructions for our sewers. 

Much like our fabric cutting patterns, we also optimize how we cut foam components—which allows us to accurately evaluate the foam consumption of each product. This image shows the blade path for a foam contour machine. 

We aim for the highest-efficiency manufacturing and try to minimize the amount of scrap our production floor creates. However, all scrap is reused as filler in several of Jaxx’s beanbag lines. 

Pattern parts move through a series of specialized sewing stations (e.g., zipper machine, lockstitch machine, etc.), reaching the end of the conveyor as a finished product. We clock these times to gauge our true cost on a new design.

After we’ve validated the product, my team starts to create marketing materials. We believe great design is important—but not if it doesn’t reach people. We want our products to quickly gain traction and marketing helps us do this.

Once all of the details of the design, construction, manufacturing, and creative assets are complete—we launch the product. These are the first batch of Jaxx Zipline Jr. Love Seats about to be packaged and sent to consumers.