How Bean Bag Chairs are Made

The following outline describes the process of making a bean bag chair. Bean bag chairs are fun and fashionable ways to create a cozy environment in your home. When constructing a bean bag, close attention is paid to detail and only the finest materials are used.

1. Materials Preparation - High quality materials are purchased from reputable suppliers. The fabric is unrolled onto large cutting tables and is thoroughly inspected for scuffs, discoloration, or any unsightly blemish that would ruin the appearance of the finished product.
2. Cutting - Once the fabric has passed inspection, it is marked for cutting. After the patterns have been outlined, precision tools cut the material into the desired shapes of the panels of the chair. Each chair has a different number and size of panels depending on the size of the chair. Typically, larger chairs have more panels than smaller chairs.
3. Sewing - After all the individual panels are cut from the large sheet of fabric, they are taken to the sewing room. In this stage, professional sewers assemble all the panels to create the jacket of the bean bag chair. Every seam of the bag is double or triple-stitched for added strength. A heavy duty thread or single untwisted filament (mono-filament) of nylon is used depending on the product. This creates added durability to handle heavy loads. It is also at this stage where the bottoms of the bags are sewn together. Each bag will have two zippers for added safety.
4. Filling the Bag - The next stage of the process is stuffing the bean bag chair with the polystyrene beads. This is done in done using large canopy-like structures that hang from the ceiling. These large tanks are filled with the polystyrene filler that goes inside the bean bag chairs. The bean bag jacket is placed to the mouth of the filling port and the beads are gravity fed into the jacket.
5. Safety Lock & Zippers - Once the bag has been completely filled, the inner zipper is zipped up. Another childproof zipper is fastened as well. This childproof lock keeps children from opening the bag, which could create a mess and possibly be a choking hazard. Click here for instructions on how to open the safety safety zipper.
6. Cleaning - The last step is to clean the bag from any excess beads that may be stuck to the bag due to static electricity. Compressed air hoses are used to remove any of the debris. The bags are put in a box and they are then ready to be shipped.