Our Manufacturing Process
Functional Stairs is a stair-tread manufacturer in Livonia, Michigan. We turn vinyl flooring — LVT, SPC, WPC, loose lay, and laminate, from any manufacturer — into seamless, custom stair treads and risers using a proprietary, high-speed automated system and a patent-pending vinyl bending process.
A proprietary, high-speed automated system
We’re not a reseller or a job shop running someone else’s equipment. Functional Stairs designed and built its own automated line for stair-tread fabrication, including a patent-pending vinyl bending process that is ours alone. The system shapes each tread in about 30 seconds and holds tight, repeatable tolerances order after order — so quality never depends on a single craftsman’s hand or schedule, and capacity scales with your volume.
How a flat plank becomes a finished tread
- You supply or specify the vinyl. Send us the flooring you’re already installing — any manufacturer, any style — or name the product and color.
- We cut and thermo-bend it on our automated line into a seamless tread with an integrated bullnose and riser return — no metal or plastic nose caps, no gaps.
- We match, inspect, and tag each tread to the floor it belongs to.
- We package and ship ready-to-install treads to your shop or jobsite, nationwide.
The problem we solve
Traditional stairs rely on bulky metal or plastic stair-nose moldings that never quite match the floor and leave visible gaps and seams. Our process wraps your actual flooring around the step for a seamless, matching stair that looks built-in — the same plank on the floor and the stairs, edge to edge.
Materials & compliance
- Works with: vinyl / LVT, SPC, WPC, loose lay, and laminate (laminate via our alternative laminate process).
- Any manufacturer: we match the tread to the plank your customer is installing.
- Built to spec: our tread profile is designed to meet 2010 ADA and applicable IBC stair dimensional requirements when properly installed. See the full Product Data Sheet.
Capacity, lead time & shipping
- Volume built for the trade: our automated line scales for dealers, contractors, builders, and manufacturers.
- Lead time: approximately 2 weeks for orders up to 2,000 units; expedited production available.
- Nationwide shipping: free pickup, delivery, or shipping on orders over $800. See Nationwide Shipping.
Order Custom Stair Treads → or request wholesale pricing
