Unveiling Craft and Precision

A Look Inside the Sabin Production Process with the Craft and Production Coordinator and Sewing Specialist

innovation, precision, and artistry

At Sabin, every product is not just an outcome; it's a carefully orchestrated process of precision, artistry, and innovation. Our commitment to pushing the boundaries of craftsmanship and technology is evident through our precise seams and artful designs.

Our philosophy revolves around the fusion of innovation and timelessness. We are not just creators; we are artists who weave technology seamlessly into the fabric of our product designs. The seams and folds are not merely design elements; they are a dance between cutting-edge technology and hand applied techniques. The interplay of folds, seams, and shadows is a result of our meticulously methodical process.  

To unpack the specifics of the Sabin production process, we sat down with two key figures behind the scenes: Becca Tarockoff, the Craft and Production Coordinator, and Salvador Reveles, the Sewing Specialist. Their insights provide an unprecedented glimpse into the heart of Sabin’s creative engine. 

Join us as we peel back the layers of innovation, precision, and artistry that define Sabin craft.

The Sabin process combines both technology and craftsmanship. Tell us more about how using the cutting and folding technology has been helpful to your process. 

Becca — We take every millimeter seriously – it can really affect the outcome and it's really nice to have a cutting machine as a tool, so everything can be as close to perfect as possible. We have also worked with our manufacturing engineer to help come up with jigs and fixturing to improve our sewing as well. It just makes life easier for the craftsperson who is making the product and also helps improve our consistency of quality for each product.

Can you walk us through the process of preparing to sew a project? 

Becca — Cut files are generated from a computer based on the measurement from the product the customer orders.  We then send the files through an automated cutting machine that can also print on the material as well. Then, we organize materials for each order before starting this process to reduce risk of error and deliver a more efficient process. We collect the scraps from each cut (see below how we plan to recycle the scraps). No scrap ever leaves the factory. 

 

What's the first step and the final step of sewing a unit for a project? 

Salvador — Sewing is in the middle of the pre-assembly process. Based on the order, I must first ensure the thread color and fabric colors are correct. Then, I sew all of the same color thread at one time - this way I don’t need to switch out the bobbins. This systematic thread color-coordinated arrangement maximizes efficiency and reduces errors. Depending on the product we even iron the fabric to ensure a clean appearance. Once all the sewing is complete, the product enters assembly.

 

What parts of the prototyping or order processes generally are the most time consuming, and why?  

Salvador — For me, ensuring all edges and sewing lines are aligned continues to be time consuming. Even as the organization has evolved and the time it takes for certain steps in the prototyping process as been streamlined due to innovation – there is still tedious manual work involved to ensure precision. The technology is an incredibly helpful tool to us; but we are the ones closely managing the tools.

 

Linear, Block, and Cylinder were our first products to be released, and I'm sure you can sew them with your eyes closed. What learnings, techniques, or methods have you come across after sewing hundreds of these? 

Becca — Due to the durable structure of the material, some of the felt can be difficult to work with during the sewing process. We introduced the use of silicone spray at Sabin to prevent fabric from sticking together - something I learned when I worked previously in upholstery. These techniques are done manually to deliver a more clean/tailored appearance.  We also use a small hand stapler to help line up all of our patterns so they stay in place when we sew them, so everything lines up how it should be. The staples get removed after a product is sewn.  

 

Layer is Unique in its construction compared to other products, mostly due to its thin profile. Tell us more about the process of sewing and constructing Layer.  

Salvador — With all Sabin products we are aware of the precision required and attention to detail needed through every step of the product development process. When we prototyped Layer, it took too many steps to complete the sewing portion. I optimized the process by making it one piece, creating fold that seamlessly hides the interior parts creating a cleaner more tailored appearance, while reducing sewing time. 

 

Sabin process combines both technology and craftsmanship. Tell us more about how using this kind of technology has been helpful to your process. 

Becca — What’s great about being a maker in todays age is that we have access to tools to help make our process easier for the craftsperson and more accurate for production. All this helps make our product be more fine-tuned so we can focus more on the making of the thing with less stress on the person making it. Here at Sabin, we enjoy what we do. Using knowledge we have from our own professional experience, we collaborated with our in house designers to help create patterns so we don’t have to do them by hand, this makes life easier on the maker, and makes a better end-result. It also really helps with production time, and also again really helps us make sure our craftspeople can focus on their skill of sewing.

The great thing about sewing is if you look close enough, you can tell a person was behind each stitch. Combining the tools we use with the knowledge we have really allows us to focus on the craftsmanship of each product.

 

What is the latest news in the Sewing and Production Department? 

Becca — We have a new and extremely large sewing machine, typically used to sew mattress toppers. It has the ability to sew through the 1.5 mm and 9 mm materials. Due to its multi-directional sewing capabilities, it allows us endless possibilities. We have already tested it for future unique decorative stitching options.  

We also installed a double needle machine which has helped to drive efficiency for our Linear product line, and we recently got the Cadillac of sewing machines that we are excited to use here on the floor. It has lots of bells and whistles that some of our other machines don’t have.  

 

Rumor has it, there is a scrap pile of PET material piling up in a corner. What are the plans for these scraps? 

Becca — It has grown immensely over the last few months as we complete more orders. These scraps will be given a second life in future products – supporting Sabin’s commitment to deliver a positive impact on our planet. We will be re-purposing our scrap and implementing it in future products where we can. This is great because instead of our scrap going to a landfill it is going directly into our products. It will help with noise reduction and help bring some new products into a new dimension.  

Learn more about the Sabin process →