About the Author

Yusuke Higuchi

Nationally Certified First-Class Tatami Master Owner of Higuchi Tatami Shop, Tokyo

Yusuke Higuchi is a premier tatami craftsman based in Tokyo, Japan, dedicated to delivering authentic Japanese comfort to homes worldwide. He perfected his craft in Kyoto under the tutelage of a "Contemporary Master Craftsman" (Medal with Yellow Ribbon recipient), mastering the millimeter-level precision required for temples and high-end tea rooms.

• 🏆 Award: Winner of the Kyoto Tatami Competition (Governor’s Award)
• 📜 Certification: National Level 1 Tatami Craftsmanship (The highest in Japan)
• 🌎 Global Service: Specializing in custom-made tatami mats for international shipping.

How Tatami Mats Are Made

A Complete Guide by a Certified Master Craftsman (With Video)

Introduction

Hello, I’m Yusuke Higuchi, a certified first-class tatami craftsman based in Tokyo, Japan.

Have you ever wondered:

• How are tatami mats actually made?
• Why do some tatami last decades while others wear out quickly?
• What is the difference between machine-made and handmade tatami?

👉 The answer is simple:

👉 Tatami quality is determined by how it is made.

Even if two tatami mats look identical at first,
their durability and comfort can be completely different over time.

In this guide, I will walk you through:

👉 The complete tatami-making process
👉 Traditional hand-stitching techniques
👉 Why craftsmanship matters for long-term quality

Watch the Full Tatami-Making Process

Watch the full process in this video.

👉 This video shows the entire process of making tatami by hand.

As you watch, pay attention to:

👉 How each step contributes to durability and precision

Why Tatami Quality Varies So Much

Many people assume tatami is a simple product.

In reality:

👉 Tatami is a fully custom-made flooring system

Every room is slightly different:

• Walls are not perfectly straight
• Floors may have subtle unevenness
• Older homes often shift over time

👉 A skilled craftsman adjusts each tatami mat
👉 to fit the exact conditions of the room

Without this adjustment, problems occur:

• Gaps between mats
• Uneven surfaces
• Premature wear

👉 This is why craftsmanship matters.

The Tatami-Making Process (Step-by-Step)

Each step has a specific purpose.
Together, they determine how long the tatami will last.

1. Measurement – Reading the Room

Tatami is not made in standard sizes.

👉 Each mat is custom-measured

The craftsman analyzes:

• Room distortion
• Floor condition
• Wall alignment

👉 Even a few millimeters make a difference

2. Base Adjustment – Creating the Foundation

The tatami base (tatami-doko) determines:

• Comfort
• Stability
• Weight distribution

👉 Adjustments are made to ensure even support

3. Preparing the Surface (Maedate)

This step creates proper tension in the tatami surface.

👉 If tension is too weak:

• Wrinkles appear
• The surface becomes loose

👉 If done correctly:

👉 The surface stays smooth for years

4. Kamachi Stitching – Preventing Sagging

This is one of the most important steps.

The surface is tightly secured using hand stitching.

👉 With proper tension:

👉 The tatami will not sag—even after decades

Machine stitching cannot achieve the same level of control.

▶︎Why Hand-Stitched Tatami Lasts 40 Years: The Art of "Kamachi Sewing" (Video Inside)

5. Karakuri – Structural Edge Control

A traditional Kyoto technique.

Purpose:

• Improves tightness
• Prevents mold issues
• Strengthens the structure

👉 This step is rarely used outside traditional craftsmanship.

▶︎What Is “Karakuri” in Tatami Making?

6. Hirazashi – Edge Stitching

This is the process of attaching the decorative edge.

Key techniques include:

• Crossing threads internally for strength
• Precise needle positioning
• Balanced tension control

👉 This step determines the visual finish of tatami

▶︎What Is Hirazashi? Traditional Tatami Edge Stitching Explained by a Master Craftsman

7. Corner Finishing – Durability and Shape

Tatami corners receive the most stress.

They must be carefully reinforced to:

• Prevent rounding
• Maintain sharp edges
• Preserve the overall appearance

👉 This is where true craftsmanship becomes visible over time.

8. Sumi-Zukuri – Corner Reinforcement (The Key to Longevity)

Tatami corners are the most vulnerable part of the mat.

They are constantly exposed to:

• Friction from walking
• Contact with furniture
• Daily wear and impact

If corners are poorly constructed:

• They become rounded
• Gaps appear between tatami
• The overall appearance deteriorates

👉 This is why Sumi-Zukuri (corner finishing) is essential.

▶︎How to Identify Quality Tatami: Mastering the "Sumi-Zukuri" Corner Technique

Hand-Stitched vs Machine-Fixed Corners

In modern production, some tatami corners are fixed using a tacker (stapling tool).

However, this method has drawbacks:

• It can damage the internal wooden frame
• It leaves visible marks
• It provides less flexibility and strength over time

In traditional craftsmanship:

👉 Corners are carefully hand-stitched

This method:

• Protects the internal structure
• Creates strong, tight corners
• Maintains sharp edges for years

👉 Well-made corners remain sharp even after long-term use

Why It Matters

You can often judge the quality of tatami by its corners.

👉 Clean, sharp corners = high craftsmanship
👉 Rounded corners = poor durability

👉 Sumi-Zukuri is where craftsmanship becomes visible over time

Why Handcrafted Tatami Is Different

Modern tatami production often relies on machines.

Machines:

• Apply uniform force
• Follow fixed patterns
• Cannot adapt to subtle variations

Hand stitching allows:

• Adjusting tension in real time
• Adapting to material conditions
• Responding to room distortion

👉 This results in:

👉 Longer lifespan and better performance

Training and Experience Matter

I trained in Kyoto, the traditional center of tatami craftsmanship.

During my apprenticeship:

• I repeated the same techniques hundreds of times
• I learned precision down to the millimeter
• I developed the ability to “read” materials by touch

👉 This foundation allows me to handle:

• Custom tatami
• Thin tatami (modern styles)
• International orders

Conclusion: Tatami Is Defined by Its Process

Tatami mats may look similar at first.

But over time, the difference becomes clear:

• No gaps
• No sagging
• Clean, sharp edges

👉 These are not accidents

👉 They are the result of proper craftsmanship

👉 The process determines everything

About Our Tatami Services

At Higuchi Tatami Shop:

👉 All tatami are crafted by a certified first-class craftsman
👉 Every step is carefully controlled

We offer:

• New tatami installation
• Tatami replacement
• Custom-made tatami
• International shipping worldwide

👉 If you are interested, feel free to contact us.

Learn More

• About our craftsman：Profile of Yusuke Higuchi, Tatami Craftsman Trained in Kyoto and Owner of Higuchi Tatami Shop
• Our craftsmanship philosophy：Solving 3 Common Tatami Problems with a Craftsman's "Invisible Techniques"　
• Contact us：Higuchi Tatami Shop - Contact Form for International Customers