How are Bean Bag Chairs made?

Bean bag chairs are fun and trendy ways to provide comfortable seating in your home. Since they take quite a beating with people tossing themselves onto them, and children jumping on them when playing, they need to be made to be extremely durable, to ensure that they last a long time. Only the best materials are used in their manufacture, with close attention being paid to every detail. Following are the different steps in the making of these cozy and unique chairs.

Step 1 -- Preparation of the Materials 
Top quality materials are selected and bought from reputable fabric suppliers. Large cutting tables are then used to unroll the material and examine it thoroughly for scuff marks, blemishes, and discoloration that would spoil the overall look of the finished product.

Step 2 -- Cutting 
After passing inspection, the fabric has to be marked for cutting. Outlines are made of the pattern pieces, and then special precision tools are used to cut the material into the shapes of the different panels that make up the chair. Each chair size has different sizes and number of panels, with the larger chairs having more and larger panels than the smaller chairs, and so forth.

Step 3 -- Stitching
Once all the panels have been cut out, they are taken to the sewing room to be stitched up and assembled by professionals to create the bag for the chair. To make sure that the bag is exceptionally strong, each seam is double or tripled stitched for extra strength. Depending on the fabric used, a single untwisted filament, or heavy duty thread made of nylon, is used for the sewing process. This reinforces the seams even further to cope with heavy loads. At this stage, the bottom sections of the bags are also sewn together. Two zippers are sewn into each bag too, for extra safety.

Step 4 -- Adding the filling to the bag

The next stage of the manufacturing process is adding the filling of polystyrene beads to the bag, which is done using big canopy-like tanks that are suspended from the ceiling and filled with the polystyrene filler beads. The stitched bag is placed at the mouth of the filling funnel of the tank, and then gravity filled with the polystyrene beads.

Step 5 -- Childproof safety lock and zippers
The polystyrene beads used to fill the bag will create a huge mess or be a potential choking hazard to a small child, should they fall out of the bag, so precautionary measures are added to the bag to prevent this from happening. After being filled completely, the inner zipper is closed, and another child proof zipper fastened as well, locking the zip, and making it almost impossible for a child to open the bag. Instructions on how to open the safety zipper usually accompany the bean bag when they are sold to clients.

Step 6 -- Cleaning before packaging
The final step in the manufacture of bean bag chairs, is to use compressed air hoses to clean off excess beads that have stuck to the bag due to static electricity. Once the bag is cleaned of all debris, it is boxed and taken to the shipping department, ready to be sent off to customers.