Craftsmanship

Continuing to develop even after succession
The craftsmanship behind NychairX

The design blueprint for Nychair X was lost, and after acquiring the rights to continue manufacturing Nychair X, the chair had to be developed from scratch, based on the original product.

There are only 6 different components used. It is a simple design with no embellishments, but since every single part plays a role in the overall beauty and is directly connected to safety and comfort, there can be no shortcuts. Below, we would like to present the thought that has gone into crafting each component.

Seat fabric

Durable and thick fabric to support your body

Fabric manufacturing
In order to maintain the strength necessary to comfortably support body weight when seated, the seat is made using twill weaving technique, the same as used in denim. To recreate the Nii’s idea of “softness as if it was washed once”, the fabric’s surface undergoes a process where it is scratched to make it fluffier. Usually, the dyeing and water-repellent finishing are done at the same time after weaving, but our process is different: after dyeing, the fabric first undergoes the fluffing process, and then a water-repellent finishing is applied.

Takeshi Nii, being a third-generation owner of a company manufacturing kendo equipment, developed this unique seat fabric with inspiration from kendo uniforms and equipment bags. It is said he soaked the fabric in water and checked the tension with his feet. Currently, production is divided between two factories: one in Kurashiki, Okayama prefecture, and another in Takashima, Shiga prefecture. The weaving, processing, and dyeing are supported by a technological insight of multiple workshops to manufacture the final fabric.

Twill weave
In comparison to plain weave, which uses one warp per one weft thread crossed at right angles, in twill weave, a single warp thread crosses multiple weft threads. Using this method, yarn can be woven into dense, thick fabric that has a soft to touch and fluffy texture, excellent elasticity, and does not wrinkle easily.

Manufacturing patterned fabric for Shikiri series
The fabrics used in the Nychair X series and Nychair X 80 are dyed after weaving, but it is different for the distinctive pattern fabrics used in Shikiri, where the yarn is dyed first and the pattern is made using colored yarns. The thickness of the stripes in patterns is carefully adjusted thread by thread, remaining faithful to the original designs made by Rika Kawato. All three Shikiri colors use one thread in a common color, so when the different Shikiri chairs are placed together, they feel well coordinated.

Fabric sewing
To improve work speed and reinforce fabric areas stressed when seating, we are using a sewing technique called double stitching, also used in sewing jeans. The first generation of Nychair X used single-needle sewing machines, and both stitches were made separately; now we are able to make both stitches at the same time, which is more cost-effective and has allowed us to increase the production volume.

Thanks to reinforced stitches in the seat’s back, it was possible to minimize the friction caused by pipes when opening and closing the chair, which led to an improvement in durability.

Since the fabric is sewn with up to seven folds, the strain on the needle and thread is heavy, so the process can be easily distorted. Even a small change can lead to sewing defects, so the machinery is backed by the exquisite handwork of experienced craftsmen.

Armrests

Natural and reliable material for parts that touch the body

Wood was used for armrests – the parts that are the most frequently touched – from the beginning, stemming from the thought that “natural materials are better because they make you feel relieved”. The structure of a human arm was taken into consideration to design armrests that prevent fatigue.

Armrests are attached by only two screws, so even a small error in hole positioning might affect the angle of the frame and have a huge impact on the level of comfort. After trial and error, we have introduced a computer-controlled dedicated processing machine for Nychair X. Because the machine does everything from shaping the wood to making holes in the armrest, it has improved cost-efficiency, production volume, and precision.

There are different colors used across the different product series, but in light-colored Natural and Soap Finish armrests, the wood grain and knots are highly visible, so to ensure the color and shades are coordinated in both armrests, final control is performed with human eyes.

Natural (urethane resin coating)

Dark Brown (urethane resin coating)

Soap Finish (for Shikiri series)

Charcoal Black (urethane resin coating; for Shikiri series)

LIMITED: Oil Finish

Oil finish and environmental consideration
To enjoy the unique personality of the wood, expressed in knots and grain patterns, and to enjoy the wood aging beautifully over time, we have released a limited edition of Nychair X Oil Finish. In order to continue manufacturing for a long time, we will continue to flexibly adapt to changes in the natural environment.

Seat pipes

Simple design requires precision in drilling

In Nychair X seat is connected to the armrests by one type of screw in four places, which requires precise calculations to ensure the placement of the screws is aligned.

Previously used cutting drills were replaced with lasers to prevent difficulties with assembly. The change made it possible to eliminate subtle position changes during processing and residue inside and outside the pipe, which were the reason for problems when threading the screws.

Leg pipes

Advancement in bending technology, focus on beauty

The pipes are formed by folding a stainless steel sheet into a tubular shape and welding the connecting ends together. To prevent spoiling the beauty of the legs, the inside of the hole is inspected, and the processing is done after making sure the welding marks are facing the inside.

Craftsmanship Details Leg Pipe Image 2 — Left: The first generation model Right: A shift to stainless steel

The first generation model utilized regular steel, but being prone to rusting over time was a disadvantage. To allow users to enjoy NychairX for longer, the material was changed to stainless steel.

The pipes are finished with a hairline matte surface to prevent excess shine and allow the chair to blend with an interior better. Additionally, it also helps conceal any scratches on the pipes that might develop during continuous usage. There is no need for maintenance, such as repairs or coating, and the chair can be loved for many years while retaining its beauty.

Screws

Tightens firmly, easy to unscrew, resistant to rust

To avoid breakage due to deterioration and prevent rust, which can make a screw unmovable, we have used stainless steel in new generation model instead of regular steel.

Since it was first released, NychairX has been made to be easy to assemble and disassemble; only cross-head screws are used, allowing assembly with a single Phillips screwdriver, which can be found in almost any household. However, because the screws connecting the two leg pipes were prone to loosening over time, we have used screws that tighten more firmly for elements not requiring assembly.

Nychair X 80 has many moving parts, and compared to Nychair X, the screws are more vulnerable to loosening due to the chair's construction. To address this issue, the screws are coated with a special lubricant, which makes it harder to loosen them.