From Raw Materials to Final Testing: The Complete Process of Crafting a High-Quality Dining Chair

Hello everyone, my name is Sunbin Qi, and I am the CEO of ASKT. I have spent more than 20 years serving furniture retailers and wholesalers across Europe, including Germany, the Netherlands, and Switzerland. Through my extensive experience, I have learned how important it is for buyers to understand every step of the product creation process, especially when it comes to something as fundamental as a dining chair. After all, the dining chair is not just another piece of furniture—it is a centerpiece where families gather for meals, stories, and memorable moments.

In this article, I want to give you an in-depth look at how we craft our dining chairs, from the very beginning when we source raw materials, to the final steps of testing and ensuring durability. By sharing this information, I hope you can gain valuable insights that will help you evaluate your suppliers more effectively, and ultimately make better decisions for your business. So, let’s get started!

Understanding the Importance of Material Selection

The very first step in creating a dining chair is deciding on the raw materials. This is something I take very seriously at ASKT because the materials form the backbone of quality, comfort, and longevity. In my years of managing factories and working with global supply chains, I’ve seen firsthand how seemingly minor choices in wood, steel, foam, or fabric can dramatically influence the final product.

1.1. Wood, Metal, or Both?

One of the biggest questions when making a dining chair is whether to use wood, metal, or a combination of the two for the frame. The choice usually depends on the desired style, structural needs, and budget parameters.

Solid Wood: Often chosen for its classic look and sturdy feel, solid wood frames bring natural warmth to any dining room. At ASKT, we typically source oak, beech, or ash woods, as these species provide an excellent blend of strength and aesthetics.
Metal Frames: When we want a modern or industrial flair, metal frames are the go-to. We work primarily with steel for its high tensile strength and durability. In some designs, we incorporate aluminum to reduce weight and add a sleek finish.
Hybrid Frames: Sometimes, designs call for a blend of wood and metal—wooden legs with a metal support bracket, or a metal base with wooden seat elements. Such hybrid constructions combine the warmth of wood with the structural rigidity of metal.

Whichever option we go for, the key is ensuring the highest quality. This is why I personally inspect and audit the suppliers for timber and steel. We look for certifications and consistent quality in grain, moisture content (for wood), and thickness or gauge (for metals).

1.2. Fabric or Faux Leather? The Upholstery Dilemma

Upholstery is arguably one of the most critical parts of a dining chair because it directly impacts comfort and visual appeal. Given my background in European furniture retailing, I’m well aware that buyers have diverse preferences: some swear by the luxurious feel of premium fabrics, while others prefer easy-to-clean faux leather or genuine leather.

Fabric: We offer a wide range, from polyester blends to velvet and high-quality woven textiles. Factors we consider include abrasion resistance (e.g., Martindale or Wyzenbeek tests), pilling resistance, and color fastness.
Faux Leather: This material is popular for its ease of cleaning and consistent color. Plus, faux leather can be more budget-friendly and eco-conscious compared to genuine leather.
Real Leather: For high-end projects, we also handle top-grain or full-grain leather. The natural textures of leather bring a premium touch to dining chairs, although it does require special care in the manufacturing process to avoid damage and maintain quality.

Because we serve various European markets, we maintain an extensive upholstery library. I make sure all materials come with REACH compliance or meet other European regulations. Additionally, we conduct color fastness tests in our in-house laboratory. We want our chairs to remain vibrant after many years of use, even in sunny dining rooms.

1.3. Foam and Cushioning Considerations

Even the best frame and upholstery won’t matter much if the foam or cushioning is subpar. Comfort is paramount. It’s not just about the softness but also about ergonomic support. We generally use high-resilience (HR) foam or polyurethane foam with varied densities. The seat may have a firmer foam than the backrest to provide better posture support.

We test for:

Compression: How well the foam maintains its shape over time.
Resilience: The foam’s ability to bounce back after continuous use.
Toxic Emissions: Ensuring it’s free from harmful substances and meets all safety norms.

1.4. Sustainable Packaging Materials

One aspect I’m very proud of at ASKT is our dedication to sustainability. We have been shifting towards honeycomb paper packaging instead of using excessive plastic or foam. Honeycomb paper offers excellent protection during transit while cutting down on plastic waste. This not only aligns with our company values but also resonates with many European buyers who prioritize environmental responsibility.

Designing the Chair for Comfort and Purpose

After choosing the right materials, the next big step is designing the chair. During my years in the industry, I have realized that even the most beautiful chair will fail if it’s not comfortable for extended periods of sitting.

2.1. Ergonomics: The Key to Long-Term Comfort

A dining chair is more than a seat—it’s where people enjoy meals, linger over coffee, or gather for discussions. So, it must provide optimal ergonomic support.

Seat Height: Typically, dining chairs have a seat height of around 45–48 cm. However, based on market feedback, we can customize to suit end-users of different heights or table designs.
Seat Depth: We aim for a depth that supports the thighs without cutting off circulation behind the knees. This is typically around 40–45 cm.
Backrest Angle and Support: The backrest should encourage an upright posture but still allow a slight recline for comfort. Our design team tests multiple angles, usually in the range of 95–105 degrees, to see which offers the best support for the lower and mid-back.

2.2. Style, Aesthetics, and Cohesion with Interiors

While ergonomics matter for comfort, style can’t be overlooked. My R&D team in China keeps a close watch on furniture trends in Germany, the Netherlands, and other European markets. Modern consumers often blend styles—Scandinavian minimalism, mid-century modern, or industrial chic.

Color Palette: Neutrals like gray, beige, and charcoal dominate in many markets. However, we frequently introduce accent colors (e.g., navy, emerald green) to align with emerging trends.
Frame Shapes: Clean lines and curved silhouettes are popular, but we also see a resurgence of geometric, angular designs. Our advanced CNC machines allow for precise cutting of wood or metal components in complex shapes.
Modular Design: Some B2B clients prefer chairs that can be assembled on-site to save on shipping costs. For these customers, we design knock-down (KD) chair options, ensuring they remain sturdy and easy to assemble.

2.3. Prototyping and Adjusting

One of the most exciting stages for me is prototyping. We have a 1,200-square-meter R&D center that includes a dedicated sample production room. We create prototypes to test functionality, refine aesthetics, and confirm that all design elements match our initial vision.

Ergonomic Tests: We invite team members of different heights and weights to try out prototypes. This user feedback is invaluable.
Manufacturing Feasibility: Some designs look spectacular on paper but might be too challenging or expensive to produce at scale. Our production experts analyze each prototype for feasibility.
Material Compatibility: We check if the selected upholstery, foam density, and frame materials all work harmoniously together.

The Step-by-Step Manufacturing Process

Once the design is finalized, we move to production. This is where my 20+ years of experience in managing factories really come to life. I’ve invested time and resources to ensure every step is optimized, from welding technology to final assembly.

3.1. Frame Fabrication

Wood Processing: If the chair is wooden, we start by cutting and shaping the wooden components. We use precision woodworking machines—like CNC routers—for consistent cuts. Moisture content is strictly monitored to prevent cracks or warping later. If necessary, we apply a wood treatment for added durability and termite resistance.
Metal Welding: For metal frames, we rely on automated welding machines that guarantee strong, consistent welds. We also have 12 advanced testing equipment that help us check for micro-cracks and structural integrity.
Polishing and Finishing: After the main frame is formed, it undergoes grinding or smoothing, ensuring no sharp edges. If it’s a metal frame, we apply a protective finish—such as powder coating or plating—to prevent rust and enhance aesthetics.

3.2. Cutting and Sewing Upholstery

Once the frames are ready, we shift our attention to the upholstery materials.

Pattern Cutting: Our pattern cutter with 20 years of experience ensures each fabric or faux leather piece is cut precisely. This step is crucial: even a small deviation can lead to wrinkles or misfits.
Sewing and Stitching: We use industrial sewing machines designed for heavy-duty fabrics. Stitches are consistent, edges are reinforced, and we often incorporate piping or decorative seams depending on the style.
Foam Shaping: The foam must fit perfectly into the upholstery shell. We cut foam based on the design templates, sometimes layering different densities (e.g., firmer foam at the base and softer foam on top).

3.3. Upholstery Assembly and Attachment

After the upholstery components are prepared, they are attached to the frame.

Adhesives: We use water-based, low-VOC adhesives to fix foam onto wooden or metal substrates. This is better for the environment and for factory workers.
Stapling and Tacking: For chairs that have fabric wrapped around the frame, staples or tacks securely fasten the material. We also have specialized clips to reduce the need for excessive stapling.
Final Aesthetic Checks: Our quality control team inspects the upholstery for wrinkles, loose threads, or uneven seams. We make immediate corrections before moving on.

3.4. Assembly Line Efficiency

Large-scale production is a balancing act between speed and meticulousness. At ASKT, we have an assembly line approach that ensures each station focuses on a specific task—from foam application to final packaging. This not only improves efficiency but also makes it easier to identify and correct any errors along the way.

Ensuring a Quality Factory Environment

No manufacturing process is truly complete without ensuring a safe and quality-focused factory environment. I’ve personally led many initiatives to enhance our workshops, not just for compliance but to create a culture of responsibility and craftsmanship.

4.1. ISO9001 Certificates and Standards

We are ISO9001 certified, which establishes rigorous quality management standards in our operations. This includes:

Documentation of Processes: From material sourcing to packaging, every procedure is standardized and documented.
Employee Training: Each worker undergoes extensive training to ensure they understand quality protocols and safety guidelines.
Continuous Improvement: We regularly audit our processes, gather feedback, and refine our procedures for greater efficiency and consistency.

4.2. Worker Safety and Welfare

A happy, safe workforce is essential for producing top-notch furniture. We enforce strict safety protocols:

Protective Gear: Welders and woodworkers wear goggles, gloves, and other safety equipment.
Regular Health Checks: Our staff have access to regular medical check-ups and a clean, ventilated environment.
Feedback Channels: Employees can voice concerns or suggestions directly to management. This open culture often leads to innovations and improved practices on the shop floor.

4.3. Environmental Considerations

Being mindful of the environment is essential in modern manufacturing. We have:

Waste Management Systems: Scrap wood is often repurposed or recycled. Metal offcuts are collected for recycling.
Emission Controls: Our finishing processes, especially for metals, comply with environmental regulations on VOC emissions.
Green Energy: In some of our facilities, we’ve installed solar panels to reduce reliance on traditional power sources.

Rigorous Testing and Quality Assurance

No matter how great the design or how skilled the workmanship, every chair must undergo rigorous testing to ensure it meets global standards and, more importantly, our own high benchmarks.

5.1. In-House Physical Test Center

I’m particularly proud of our investment in 12 specialized testing machines that allow us to thoroughly evaluate every aspect of a dining chair:

1. Color Fastness Test: Ensures upholstery doesn’t fade or bleed even after prolonged exposure to sunlight or abrasion.

2. Armrest Downward Static Load Test: Tests the armrests’ ability to bear weight (especially crucial for consumers who push down on the armrests while getting up).

3. Lateral Static Load Test: Checks the chair’s stability against side forces, preventing tipping over.

4. Front End Durability Test of Seat: Simulates extended pressure on the seat edge (frequent in normal use).

5. Backward Drop Test: Ensures the chair can handle sudden backward tilts.

6. Front End Static Load Test of Seat: Checks the load capacity for the front portion of the seat.

7. Forward Static Load Test of Chair Legs: Evaluates leg strength under forward pressure.

8. Seat Impact Test: Subjects the seat to repeated impact forces to replicate someone plopping down abruptly.

9. Seat Back Joint Durability Test: Ensures the backrest joint can handle repeated stress.

10. Seat and Back Static Load Test: Measures overall capacity and joint integrity.

11. Backrest Impact Test: Repeatedly strikes the backrest to test its resilience.

12. Armrest Durability Test: Similar to #2 but includes repeated stress over time.

5.2. Our Quality Inspection Personnel

To ensure these tests are conducted properly and consistently, we have 11 quality inspection and testing personnel. Each of them wears a professional video recorder during inspections, ensuring that the entire quality inspection process is transparent and verifiable. This is crucial for trust and accountability.

Furthermore, these inspectors randomly pick samples from production runs to ensure that every batch, not just the showcase samples, meets our quality standards.

5.3. Packaging and Shipping Tests

We don’t stop at just the chair’s structural integrity. We also test the packaging:

Drop Test for Packaging: Chairs in their boxes are dropped from various heights and angles to ensure that the honeycomb paper and packaging design absorb the impact without damaging the product.
Vibration Test: We simulate the vibrations of long-distance truck or sea freight journeys. This helps us refine packaging to reduce damage rates.

Final Assembly and Presentation

Once a chair passes our strict tests, it moves to final assembly (if required) and a last round of visual inspection.

6.1. Touch-Up and Finishing

At this stage, any small flaws—like tiny paint imperfections or wrinkles in the upholstery—are addressed. If a wooden chair needs a second coat of protective finish, now is the time. We also check that all components fit perfectly, that there are no wobbles, and that each chair meets our comfort criteria.

6.2. Showroom Display

We have six sample rooms in our product showroom that recreate living scenes in Germany. I find this approach extremely useful because it lets customers visualize how the chair might fit in a real home. Some rooms have different lighting conditions, dining table sizes, and complementary furniture pieces. This helps prospective buyers see the chair in action, so to speak.

6.3. Preparing for Shipment

When the chair is fully approved and ready for shipment, we carefully wrap it in honeycomb paper, add corner protectors, and place it in a well-structured box or crate. Every package includes a label detailing the product name, color, dimensions, and assembly instructions (if KD). We also add QR codes that link to assembly videos or care instructions, making it easier for buyers to handle the product at their end.

Why These Steps Matter for You as a Buyer

You might be wondering: “Why should I care about each step in such detail?” From my perspective, understanding the entire manufacturing process helps you evaluate a supplier’s reliability and quality. Here are a few reasons:

1. Quality Assurance: By seeing how seriously a supplier takes each step—especially material selection, design, and testing—you can gauge if they will deliver consistent, defect-free products.

2. Regulatory Compliance: European markets have strict safety and environmental regulations. Knowing the production process ensures your product meets these requirements.

3. Longevity and Cost Savings: Chairs crafted with meticulous care last longer, reducing your return rates and increasing customer satisfaction.

4. Customization Opportunities: If you understand each phase, you can request specific changes—like alternative fabrics, different seat heights, or unique finishing options—more confidently and precisely.

5. Brand Reputation: Your end consumers will appreciate products that are safe, comfortable, and sustainably produced. This boosts your own brand image in a competitive market.

Conclusion and Contact Information

Crafting a dining chair might seem straightforward at first, but as you’ve seen, it involves layer upon layer of careful consideration—from raw materials and ergonomics to safety testing and packaging. I’ve spent decades refining these steps to ensure that every dining chair that leaves our factory not only meets international standards but also brings warmth, comfort, and style to dining rooms around the world.

At ASKT, we believe in transparent communication, so that you, as a furniture buyer or product manager, can trust every stage of the process. Our comprehensive approach—backed by ISO9001 certification, dedicated testing labs, and an innovative R&D center—reflects our commitment to creating furniture that you will be proud to offer your customers.

If you’re looking for a reliable partner to supply high-quality dining chairs for your retail stores, e-commerce platforms, or wholesale operations, I would love to connect with you. Let’s explore how we can collaborate and tailor solutions that meet your specific needs.

Contact me directly:

Name: Sunbin Qi
Email: sales@sinoaskt.com
WhatsApp: +86 18912605997
Website: www.asktfurniture.net

Thank you for taking the time to understand our process. I hope this article has given you valuable insights into how a high-quality dining chair is made—from raw materials to rigorous testing. If you have any questions or would like to discuss potential collaborations, please don’t hesitate to get in touch. Together, we can bring beautiful, durable, and comfortable dining chairs to homes across Europe and beyond!