Do you know how to make chairs? Let us show you the details of the Chiavari Chair manufacturing process step by step as following:
1. Material selection, precautions, and requirements
We utilize two (2) methods to select the materials. Primarily, the logs are imported by our company from the country of source. This variety of logs will be cutaccordingly for the specific use and set out to dry up to the appropriate level of moisture remains on the wood before it goes to the next Chiavari chair manufacturing process.
The second method is being done through direct purchase from suppliers in which the materials are processed and cut following our requirements and sized individually as specified. And upon receipt of the processed materials, our quality control professionals will conduct a product pass-inspection before release to our manufacturing department to ensure quality and all specifications required are met.
Within these mentioned methods of selection, an important key our skilled buyers are the task to perform thru the selection process is to delicately select each log and visually select distinctly the logs that contain the minimal amount of knots (wood knots) as these particular wood knots within the logs can easily break through the process. This sensitive selection process is essential especially for the durability of our Chiavari chairs wooden leg structure that has been marked with the guarantee to never break to the worst condition it is used for.
2. Cutting process
When we cut, we ensure to utilize the best single standardized size. The large wood is cut into square wood according to the product size required for the different parts of the wooden bamboo chair back leg, front leg, cross bracing, small column, etc. This becomes a square wooden block that comes with our chair products.
3. Type (machine engraving)
The square wooden block will be processed into a specialized machine for engraving development. (Refer to the photo) We have different machine types for each type of process specifically for Bamboo chair, back leg, front leg, cross support and our small column-out machine type that our skilled and experienced journeymen operators utilize and maintain. The tools are regularly polished and cleaned to ensure the accuracy and performance of the machine. The cutting blades are kept in its cutting-edge condition to make sure every shape is then accurately cut, fine and smooth appearance for a flawless look with no burrs before it enters the next Chiavari chair manufacturing process under a suppress camber system.
4. Parts grinding
Grinding work is an important part of the Chiavari chair manufacturing process. After all the parts are out, an initial repair and grinding work will be carried out to ensure the cleanliness and smoothness of the back chair. The grinding of the parts is usually done with a sanding machine. Combined with artificial sanding cloth that ensures every detail is smooth. At this stage, our professional quality controllers (QC) will initiate a thorough quality inspection of each polished finished product for any discrepancies. In this case, all products with faults are segregated to return to the same process until it obtains the level of finished quality required.
5. Cooking and bending (back leg, backrest)
For the back leg and back cross braces of the bamboo chair accessories, we must make the camber and use special iron molds were all the molds are at the same size and hardened. Initially, the straight wooden stick is dip into the pool, steam and hot water combined on high-temperature cooking for 20 minutes. Softening the wood and then fixed into the mold with the same curvature and placed on a high-temperature furnace for 72 hours static heating, in which the wood hind legs obtain the exact curvature we desire. After 72 hours, the hind legs are removed from the mold and prepared for assembly.
How we ensure that all parts have a camber with accurate molds in place?
This is done on the following assembly Chiavari chair manufacturing process were our skilled workers manually find the rear legs of similar angles and install them on the chair.
According to the actual assembly requirements of the chair, standardize fixed dimensions, hole spacing requirements, and the size of the holes are utilized. We send them to different machines, and the holes are bored by professional technicians. The angle and size of the holes are static for the appropriate screws specified.
7. Seat board making
For the seat plate of the bamboo chair, our general size is 40*40CM. We use a multi-layer board out of solid wood. Processed with special tools and molds. We use computer engraving control to get 12 sets of the same size at one time. After the shape of the seat plate comes out, the edge will be machined and punched as specified.
Our commitment to work efficiency is very high that every Chiavari chair manufacturing process to undertake are carried out with remarkable results on all our product line.
8. Back assembly,
Back assembly front panel assembly, overall chair assembly are explained as follow:
In the next step, we assemble the chair in several steps. First, the back of the chair is built. Therefore, the holes between the fittings and the glue are added to make the links between the accessory’s sturdy. Back assembly, front panel assembly, seat plate, front and rear panel assembly, will be structured with the hardware accessories and linked together. Tightened to the right torque for durability and strength. At this phase, 75% of the work has been completed.
9. Leveling of the legs
Another very important step and delicate process is the chair legs level accuracy. The assembled chair, regardless of whether the four legs are angled or on a horizontal line, we must put it on the leveling machine to level the four corners and let the four points be in a horizontal plane. On the top, after the nails are installed, the four corners are balanced on a horizontal line and perfectly make it a finished product.
10. Requires less maintenance
We are a manufacturer with strict policies and guidance that our leadership team implements and enforced throughout the company and its employees. Our responsibility for each of our chair products is our main concern. We take pride in our workmanship to give you a high-quality product that our name is embossed to assure a lifetime of use.
It is in our most important work ethics that these products undergo an extensive re-examination of each part and in whole for the tiniest flaw and discrepancies before packaging and shipment occur. From spilled glue, joint gaps, rough areas or unpolished parts to texture and color vibrancy and the overall appearance our skilled screeners will disapprove or reject on their assessments are generally return to manufacturing for a second run. Unfortunately, none of the rejects are being sold out. So, all you get is our product with a 101% quality guaranteed.
10.5 The following statements of the whole process described in detail directly from our manufacturing team are as follow:
11. The whole chair is polished
Our chairs are also repaired. Before we paint, we will do another overall chair grinding, using artificial, hand-held sandpaper, and sanding. An experienced worker can polish about 70 chairs a day, so you will see a lot of sanding workers in our factory, and most of the other products used the machine to processes. And we have been recruiting and cultivating excellent wooden chair polishers.
12. Primer painting
Now the whole chair has been polished and entered the paint production line. We will use the combination of paint electrostatic computer painting and manual repair, but there will be robotic painters in the future. At present, we use computer electrostatic painting to mainly Maximize the use of paint, seldom waste paint, the benefit of the paint line is that the winter is not affected by the weather, we have our drying room. Automatic the back of the chair and under the cross braces will be a little missing, we will use the experienced painter to repair. The above is theprimer part of thepaint, the bottom painting work. The color of the primer, we will choose the right primer color according to the final color requested by the customer.
13. After the primer is dried, the paint booth is polished.
Usually, we will carry out the primer twice, and after the paint is dried, it is polished to give better adhesion. As you can see from here, polishing work is very important.
14. Spray the topcoat after two times of primer
After the primer is finished, we will carry out the paint color confirmed by the customer. Sometimes the primer is not the same color as the topcoat, but the final surface painting will be the color required by the customer. We can modulate the paint through the computer. You can compare the Pantone color card number, or you can do the same color according to the color plate given by the customer.
15. Dry after two coats of paint, check the finished product
After the finish, all the chairs are finished in the natural or paint drying room. After the paint is dry, we carry out the inspection of the individual chairs before the packaging, the finished product inspection, one by one, and find any paint leaks (some If the paint is left in the area, or the paint is piled up, it will be picked out, processed, and repainted until QC feels that these chairs are very good and can be packaged.
16. Packing a single chair
Single chair We use pp foam paper to wrap each part and the whole chair, ensuring that the chairs do not rub against each other when they are stacked.
17. Loading the carton
We will put the superimposed chair in a box of the right size. Sometimes we will put the customized mat into it to save the cost of the mat.
18. Loading containers or bulk goods
Ok, now the customer’s chair is loaded into the carton, and the rest of the shipment becomes relatively simple. We send the bulk cargo to the dock, but the customer’s entire order into the container, usually our cooperative team, will go the dock pulled the corresponding container to our factory, and then we packed the carton into the container.
Our wooden Chiavari chairs are sold to more than 56 countries and regions. More production please visit our website www.blossomfurnishings.com Email: [email protected]