Private label modular foam sofa modules wanted — 6,000 pcs/year

We're building a private-label line of frameless, foam-block modular sofas for direct-to-consumer sale and are looking for a manufacturer who can produce the individual seat and corner modules to our own branding. Specification: boneless/frameless construction, high-density or memory foam fill, polyester fabric cover that's fully removable and machine-washable, square arm style, cushion-back design, so customers can combine modules into L-shapes, straight sections or single chairs. We'd want 2-3 module types (corner, armless, chaise) available in the same fabric and foam spec so they combine seamlessly. Volume: approximately 6,000 pieces per year across the module types, split roughly evenly, released in quarterly production runs rather than one annual order. Certifications: RoHS compliance and BS 5852 fire-resistance documentation are required — we sell into markets where flammability standards get checked, and we won't list the product without that paperwork on file. Packaging: compressed/vacuum-packed for parcel shipping since these ship direct to consumers' homes, not palletised freight — box weight and dimensions per module need to stay within standard parcel carrier limits. Delivery: FOB origin, we manage import and last-mile fulfillment ourselves. In your proposal, please include: pricing per module type at this volume, minimum order per module/fabric combination, lead time for the first production run versus repeat runs, and whether you can hold a few fabric colorways in stock for us to rotate periodically without full re-tooling each time.