Leather Office Chair Manufacturing
The manufacturing process of leather office chairs mainly includes steps such as making the seat frame, crafting the backrest frame, processing the leather, creating foam cushions, stitching the leather and foam, and assembling the components.
When making the seat frame, a hydraulic press bends thumb-thick steel tubes into the seat frame. After open welding, a steel bar is welded in the center, followed by hanging S-shaped springs and then fixing crossbars horizontally onto the springs. Alternatively, a hydraulic-powered machine is used to bend 14-gauge steel tubes to form the bottom cushion frame. The ends of the reinforcing bars are connected by welding to serve as the intermediate support and the mechanism for adjusting the seat position. S-shaped steel springs are hooked to the front and back of the seat frame, and iron bars are clamped horizontally between the springs to enhance stability.
Crafting the backrest frame involves components such as lumbar support, armrests, and other parts. Afterward, the burrs and rough edges on the steel bars are ground down to ensure a smooth frame surface, preventing damage to the leather during subsequent use.
In the leather processing stage, workers lay the leather flat on a table and cut it along thick cardboard templates, avoiding flawed areas. Different-shaped templates are used to cut out leather for different parts to minimize waste, with one piece of leather being sufficient for one chair. Alternatively, smooth leather hides are evenly placed on a cutting table and cut according to the templates, working around the natural defects in the leather. The cutting positions are determined through calculations to ensure that only one hide is used for the leather of one office chair.
When creating foam cushions, foam is cut to the same size as the leather. Different types of foam are used for different parts of the office chair, with tighter foam being used for the cushions. Alternatively, foam buffer pads are cut. To maintain their shape, more rigid foam is selected for the chair's contour buffering, and softer foam is chosen for the backrest. Slits reflecting design features are cut into the backrest cushions.
Stitching the leather and foam involves using a sewing machine to stitch them together one by one, which requires skill. Alternatively, chalk is used to draw lines on the corresponding positions of the leather and foam. Stitching is carried out after ensuring that the cuts align with the chalk lines on the leather. When stitching the backrest of the chair, the filling is sewn onto the pattern pieces, and then the contoured shells are sewn onto the sides.
During component assembly, first, a crushed wood veneer board is added to the backrest and entirely wrapped with foam, followed by covering it with a leather pad and then installing a plastic cover on the back. The swivel plate is locked onto the base, and an adjustable hydraulic column is installed, which supports 360-degree rotation of the chair. An aluminum base is mounted, and five casters are installed in the grooves of the base. A car-style headrest and two armrests are installed on the backrest.
