Hello everyone! I’m Higuchi from Higuchi Tatami Shop. In this blog, I unveil the story behind the development of our Foldable Tatami Mattress — “non‑slipping,” “soft,” and “lightweight.” Here’s the behind-the-scenes journey.
1. From Need to Idea: The Origin of This Product
One day, a relative asked me to make two tatami mats. They’d just moved into a studio apartment where a bed felt too bulky. They considered just using a mattress but worried about mold from sweaty nights—so they turned to tatami and asked for my help.
Initially, I thought of regular “place” tatami—mats placed directly on floors, popular in Japan. But I noticed they shift easily, with dust gathering in the gaps, making them hard to clean.
I tried adding grip pads, but using them as bedding, body heat caused them to melt and stick to the floor. So, I wondered: can I make place tatami that don’t slip—without grip pads?
Then I had the idea: connect two tatami mats. I used a traditional technique from yūsoku-datami—ceremonial tatami made for the Imperial Court and temples—sewing them together along the edges. I’d learned this in Kyoto years ago, but rarely used it after starting my shop in Tokyo. Applying that method allowed the mats to stay together without shifting. And that’s where the foldable tatami mattress idea was born.
2. Trial After Trial: A Craftsman’s Challenges
However, the finished product didn’t come easily. I encountered several issues:
🧵 A) Thread Stretching
Stitching the mats together using thread created a problem: folding and unfolding caused the thread to stretch and start showing on the surface. The edge fabric also loosened—so I had to solve it. After numerous experiments—switching to low-stretch thread and tightening the knot—I fixed it.
🎥 See It in Action
Check the demo video on YouTube: Watch Demo
🪵 B) Warping with Thick Tatami Coverings
Our mattress uses a 15–25 mm tatami base. With thick tatami covers, the mat would warp. Especially high-grade “asawata-bit-dubble” tatami covers would wrinkle unless carefully attached. I tried dozens of times until I found “Hino‑sārasa,” a premium Kumamoto-made tatami covering that works flawlessly on thin bases.
(Explanation: “asawata-bit-dubble” is a high-end tatami cover featuring two warp threads of hemp and cotton; “Hino‑sārasa” is a top-grade Kumamoto-certified variety woven from premium “Hinomidori” straw.)
🛏️ C) The Hardness of Tatami
While testing, I found tatami too firm—modern tatami is often too hard. Historically, straw-core tatami were soft enough to sleep on without mattresses.
I experimented with cushioning: chip urethane, traditional tatami cushioning, and hemp nonwoven fabric—but all softened quickly after repeated use. The breakthrough came with judo tatami padding, which is soft yet highly durable. After testing, the result was perfection: superior tatami softness that resists flattening, making it a game-changer even for mattress markets.
3. Tradition Meets Innovation: A Unique Value Proposition
When the foldable tatami mattress was complete, it felt like a modern return to the origins of tatami.
Over 1,000 years ago, tatami weren’t fixed floor coverings—they were layered on wooden floors as bedding or cushions. These stacks provided comfort and were called tatami (“foldable straw mat”). Today’s tatami evolved from that concept—but our foldable design actually folds for storage, reviving this ancient tradition.
Our mattress quietly merges tradition (exterior) with modern technique (interior) to offer unmatched value.
4. Pushing Boundaries: The Edgeless Tatami Challenge
To adapt to contemporary styles (like Scandinavian design), we decided to create edgeless tatami—no cloth border. This was extremely difficult: without edges, where would the stitching go? The process involved constant trial and error—and remains a secret technique. But if I, a single craftsman, could do it, so can others with perseverance.
That technique also allows us to produce intricate edgeless tatami—like stone-pattern folding mats or modular wall art pieces. While production is complex now, advancements will allow affordable delivery to homes.
5. Looking Ahead: The Next Challenges
🌍 A) Going Global
We’ve already received international interest—but shipping full-size tatami is costly (sending 6 mats to Mexico could exceed ¥500,000). Our foldable design allows compression and lightness—aiming for under 8 kg per mat—so we can ship affordably via EMS. By summer 2025, we expect to have a version that meets both lightweight and durability standards.
🛋️ B) Designing for Global Tastes
The current design reflects my Kyoto training—Japanese aesthetic. But moving forward, I’m developing Western-style, Chinese-style, American-style, and neutral designs that blend seamlessly with modern interiors. Stay tuned as we unlock new possibilities.
6. My Heartfelt Vision
Japanese igusa (rush) farmers are vanishing—due to aging, succession challenges, and low prices. As costs for fertilizers and threads rise, tatami covering prices can’t keep pace. If igusa farming disappears, so will authentic Japanese tatami.
At 32, I plan to work as a tatami craftsman for at least 40 more years. Losing igusa farmers terrifies me. My role is simple: keep using Japanese-grown igusa. I hope customers appreciate its value and choose authentic tatami.
If you’re curious and want to support sustainable craftsmanship, I’d be honored if you’d explore our mats.
▶︎ [Visit the product page]
Final Thoughts
This foldable tatami mattress carries so much meaning—developmental passion, cultural roots, technical innovation, global hopes, support for igusa farmers, and heartfelt wishes for customers.
After developing this product, I realized: every product in the world is infused with deep intention and care. I never considered this before—but now, I deeply respect those who commit to creating meaningful things.
Thank you so much for reading to the end.
