Due to its size - 3 x 2.8m - the SNOFA was prefabricated in six sections and made on site.
The curved carbon-fibre shell elements were bonded in the mould to 25mm rigid foam sheets, cut to accommodate the curved shapes. At the top edges the carbon fibre was wrapped over the foam so that the upholstered back seat could butt cleanly against it. The curved edge joints between adjoining carbon-fibre sections were radiused to take up the tolerance between the carbon fibre and the leather upholstery.
A skeleton frame of 18mm ply sheet was then fabricated and bonded to each shell section with epoxy; the frame has slotted holes to ventilate the AMX console and telephone.
Ply seat frames and back frames were then fixed to the skeleton.
The curve of the back frames came from laminating 1.8mmthick ply sheets together.
An assembly of traditional upholstery seating - springs, wadding, calico - was finished with a surface of high-quality cowhide leather, much of it hand-sewn to achieve the tight curves.
The AMX console and the telephone are housed in recessed compartments of ply, each fitted with a sliding door of curved aluminium clad with rolled and finished leather.
On site, the Snofa sections were bolted together through adjacent ply skeleton frames, and the seat-back upholstery panels were locked in place.