Download - Bean Bag Process
BEAN BAG PROCESS
BY : ENACTUS
R&D TEAM
BEAN BAG PROCESS
WORK SCHEDULE
8:00AM
-PUT IN 1St BATCH OF PLASTIC TO BE STERILISED
-SEWING OF 1st BATCH BEAN BAG COVERS
9:00AM
-REMOVAL OF 1st BATCH PLASTIC AND PUT IN 2nd BATCH OF PLASTIC
-CONTINUE SEWING 1st BATCH OF BEAN BAG COVERS
10:00 AM-REMOVAL OF 2nd BATCH PLASTIC AND ADDING IN NEW THE 3rd BATCH OF PLASTIC
-COMPLETION FOR THE SEWING OF 1st BATCH COVER
11:00AM
-REMOVAL OF 3rd BATCH PLASTIC AND THEN PUT IN THE 1st BATCH OF COMPLETED BEAN BAG COVER FOR STERILIZATION PROCESS
-STARTING SEWING OF 2nd BATCH BEAN BAG COVER
12:00PM
-REMOVE THE 1st BATCH BEAN BAG COVER FROM THE STERILIZER AND PUT IT TO DRY
-ADD IN THE 4th BATCH OF PLASTIC FOR STERILIZATION
2:00PM
-REMOVE 4th BATCH OF PLASTIC FROM THE STERILIZER AND PUT IN THE 5th BATCH
-CONTINUE SEWING 2nd BATCH OF BEAN BAG COVERS
1:00PM
LUNCH BREAK
3:00PM
-REMOVAL OF 5TH BATCH PLASTIC FROM STERILIZER AND PUT IN THE 6th BATCH
-COMPLETION OF 2nd BATCH SEWING OF BEAN BAG COVERS
4:00PM
-REMOVE THE 6TH BATCH OF PLASTIC FROM THE STERILIZER AND PUT IN THE 2ND BATCH OF COMPLETED BEAN BAG COVER FOR STERILIZATION PROCESS
-START FILLING PROCESS OF THE FILLERS IN THE BEAN BAGS
5:00PM
-REMOVE FINAL BATCH OF BEAN BAG COVER FROM THE STERILIZER AND SET IT TO DRY
5:30PM
-END OF DAY WORK
STERILIZATION PLASTIC AND FABRIC PROCESS
STEP 1:
HEAT UP THE STERILIZATION MACHINE
ADD WATER INTO THE BASED OF THE HUGE METAL CONTAINER, BOILED IT TILL THE TEMPERATURE STATED FOR DIFFERENT TYPES OF PLASTIC, CHECK THE THERMOMETER FOR READINGS
STEP 2:
PUT THE PLASTIC INTO THE HUGE CONTAINER FOR STERILIZATION PROCESS
STERILIZE THE PLASTIC/FABRIC FOR ABOUT 30 MINS, THEN REMOVE IT FROM THE STERILIZER AND PUT IT TO DRY UNDER THE SUN
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AUTOCLAVING MACHINE
GUIDELINE FOR PLASTIC AUTOCLAVING
Adapted from : http://www.scilabware.com/uploads/PDFs/2010/Technical_information_Plastics.pdf
PATTERN
For adult-size chair
Medium- to heavy-weight fabric for outer cover:
for fabric 45 to 48 (115 to 122 cm) wide: 5 yards (4.6m)
for fabric 54 to 60 (137 to 152.5cm) wide: 3-1/2 yards (3.2m)
Muslin for lining, yardage same as for outer cover
Zipper, 22" (56cm) long
Polystyrene or plastic pellets, approximately 6 cu. ft. (1.85 cu. m). Note that more may be needed depending on the size of your bag. Check online (we suggest Amazon.com) or with doll stuffing suppliers, packing suppliers or upholstery suppliers for sources.
Other suggested filler to use would be packing peanuts. Use the ones that DO NOT dissolve with water
1" (2.5 cm) grid, such as cutting mat or graph paper
For child-size chair
Medium- to heavy-weight fabric for outer cover:
for fabric 45 to 48 (115 to 122cm) wide: 3 yards (2.7m)
for fabric 54 to 60 (137 to 152.5cm) wide: 2-1/2 yards (2.3m)
Muslin for lining, yardage same as for outer cover
Zipper, 18" (46cm) long
Polystyrene pellets, approximately 4 cu. ft. (1.27 cu. m)
1" (2.5cm) grid, such as cutting mat or pattern paper
HOW TO SEW A BEAN BAG
Step 1: Gather Materials
3 yards of fabric for the
inner lining
3 yards of fabric from the
Michael Miller Dick and
Jane collection for the
outside cover
Scraps of coordinating
fabric for the appliqu
30 of wide hook and
loop tape
Bean bag pellets (I used
one 100 liter bag of
recycled polystyrene
pellets)
The pattern pieces at the
end of this tutorial
The inside lining and outside cover
are made the same way except for
the closure. Pictures in the tutorial
are of the outside cover.
Step 2: Cut the pieces
The bean bag chair is made up of six panels. Each yard of fabric will yield two panels, with a bit leftover (which will be used later). Fold fabric selvedge to selvedge.
Iron it on the crease. Fold it in 8 on the side and iron that crease. Cut so that you have a rectangle. (Basically you are creating a panel that if unfolded would measure 16 x 45). Place the corner of the pattern where all the
folds meet. Pin in place and cut. When unfolded, it should be football shaped.
Do this again with the remainder of the yard. You will have strip of fabric leftover. Do not discard it!
Continue cutting until you have six
panels. Figure out how you want your
panels organized for the bean bag chair
cover.
Youll be sewing your panels in groups
of three.
Step 3: Sew the panels
With right sides facing, sew two panels
together along one side. Youll want to
start and stop your stitching at
approximately 5/8 from the top and
bottom points.
Iron the seams in one direction. Do NOT
iron them open, as this creates a weak
seam. If you have a serger, use it now. If
not, dont worry about it.
Sew the second and third panels together
along one side. You now have half of a
bean bag chair!
Set this aside and sew the three
remaining panels the same way.
Now youll attach the two halves. With
right sides facing, sew the third and
fourth panels together. It can get a bit
bulky at the points, but dont worry about
making them perfect, as they will be
covered up later anyway.
Step 4:Create the closure
The outer cover will use a hook and loop
closure to allow for easy removal for
laundering. The inner cover needs to be
closed in the following way: Sew the first
and sixth panels together leaving a ten
inch opening for turning right side out
and filling. Apply the appliqus (step 3),
then fill. After filling, it should then be
hand-stitched closed.
Cut a strip of fabric 32 x 2- long.
Fold down both ends and iron them
down. Then fold the entire length of the
strip in half and iron it.
The loop tape is 30 long. Mark its
center at 15 and line that up with the
center of the strip. Place it closer to the
folded side of the strip and sew around
the perimeter of the loop tape to attach it
to the strip.
Line up the center of the strip with the
center of the panel side where it will be
attached. The loop tape should be facing
down and the raw edges should be
together. Pin in place and sew using a
seam allowance. Reinforce at the
beginning and end by backstitching.
Fold the strip over to the other side of the
panel so that the loop tape is now facing
up. Finger press it along the edge and
sew in place, backstitching when you
start and stop.
For the other panel, do the same thing
create the strip, attach the hook tape,
center it, pin it in place and sew with
hook tape facing down.
RAW EDGE
Instead of turning it to the other side of
the panel, however, the hook tape needs
to remain facing up. Make it behave by
finger pressing the seam so that it lies
under the panel. Topstitch it in place.
Make sure the bean bag cover is still
inside out. Attach the hook and loop tape
together (not all the way down, just at the
top, since youll need to get through the
opening to sew!), and sew the ends of the
strips together from A to B. Backstitch
to reinforce. Do the same for the other
end.
Remove the fabric from the machine and
readjust so that you can finish closing up
the bean bag cover. Turn the cover right
side out.
A
B
Step 5: Create and attach the appliqu
The points on the top and bottom of the
cover may or may not line up, but that
doesnt really matter because they need to
be reinforced anyway with a sturdy
appliqu. For the appliqu youll need one
piece of fabric for the top, one for the
bottom and iron-on interfacingall
measuring 4 x 4.
Iron the interfacing to the bottom piece
following the manufacturers directions.
Place the top piece face down on the
bottom piece. The interfacing needs to be
on the underside.
Trace the circle with a fabric pen and then
stitch directly on the circle, all the way
around.
Pink the edges of the circle. Carefully pull
the two fabric layers apart and cut a slit in
the bottom piece. Do not cut through any
stitching. Turn the circle right side out.
The interfacing should now be the center
layer.
Press it flat. You may need to fiddle with it
a bit to get the edges smooth.
Pin it on top of the bean bag cover where
all the points meet. Pin it so that each
panel has one pleat in it. Take special care
to ensure that the appliqu lays flat.
Zig zag around the perimeter of the
appliqu.
Attach another appliqu to the bottom in
the same way.
Insert the filled liner in the cover, and close
it up!
YOUR DONE!!!
STERILIZATION MACHINE PROPOSED IDEAS: