How It's Made - Step by Step

We start by preparing the base, making sure the warp threads (the vertical threads) are evenly tensioned.

Using a backing yarn, we create a base with just the right amount of cushioning. This helps to keep the spacing of the warp threads uniform and ensures the final width of the chair pad.

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Next, referring to a design chart (created in Excel), we begin knotting bundles of yarn onto each warp thread, gradually forming the pattern.

Preparing those yarn bundles is a crucial step in itself—we repeatedly wind yarn around a warping frame to create about 160 strands, which are then bundled into small balls of yarn.

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As each row is completed, we insert the backing yarn and beat it down firmly with the reed, then hammer it further to make it tightly packed. Since this is a floor mat, durability is essential.

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Once finished, we cut the warp threads and remove the piece from the loom. The final step is tying off the ends into decorative fringes.

It usually takes about 2 to 3 days to complete one chair pad.

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Surprisingly, it’s quite a physical job!