About the Author
Certified First-Class Tatami Craftsman / Owner of Higuchi Tatami Shop
Trained at Sawabe Tatami Co., Ltd. in Kyoto, a workshop led by a "Contemporary Master Craftsman" honored with the Medal with Yellow Ribbon, before starting his own business in Edogawa, Tokyo.
Winner of the Kyoto Tatami Competition (Governor’s Award) / Holder of the National First-Class Tatami Craftsman License.
Extensive experience from temples and shrines in Tokyo’s Edogawa ward, to private homes, tea rooms, houseboats, and guesthouses.
Experience the beauty of traditional Japanese craftsmanship through the eyes of a modern craftsman.
Two documentary-style videos produced by GOKAIDO, a company based in Mexico that exports tatami mats around the world, feature the work of Yusuke Higuchi, a tatami craftsman from Japan.
Each video offers a rare glimpse into how traditional Japanese tatami are made — from detailed hand-sewing techniques to the philosophy behind this timeless craft.
🎥 Watch the YouTube Videos
- Part 1 – Tatami Making Process (Traditional Methods)
👉 Watch on YouTube - Part 2 – Tatami Re-covering (Tatami Omote Replacement)
👉 Watch on YouTube
Part 1: The Art of Making Tatami by Hand
In the first video, Mr. Higuchi demonstrates how traditional tatami are made by hand, using methods he learned during six years of training in Kyoto.
Every process reflects the harmony between precision, patience, and respect for materials — values that define Japanese craftsmanship.
🔹 Main Highlights
- Measurement & Squaring (00:40)
Each mat is carefully measured so the corners form a perfect 90° angle. Accuracy is key. - Sewing the Tatami Omote (07:45)
Before attaching the edge (tatami beri), the tatami omote (rush grass surface) is sewn by hand — a process that requires both strength and sensitivity. - Custom Tools and Workbench (09:07–11:32)
Higuchi shows his self-made rotating stand and handmade tools, proving that a good craftsman always adapts his tools to his own needs. - Finishing Touches (10:32–22:41)
The process includes sealing stitch holes with water (as igusa swells when wet) and applying insect- and mold-preventing treatments for international shipments.
A Craftsman’s Philosophy
“Good craftsmen always know exactly where their tools are,”
Higuchi explains, emphasizing the importance of order and efficiency in traditional Japanese work culture.
Part 2: Tatami Re-covering — Giving New Life to Old Mats
The second video focuses on tatami omote replacement — a process known in Japan as “Omote-gaeri.”
Instead of replacing the entire mat, only the top layer (tatami omote) is renewed, keeping the core (tatami-doko) intact.
This sustainable approach has been part of Japanese homes for generations.
The Re-covering Process
- Adjusting Loose Threads (05:06)
Over time, the threads inside the core loosen. The craftsman adjusts the tension with needle and thread by touch — a skill honed through years of experience. - Traditional Oil Technique (09:07)
A fascinating glimpse into an old habit: using natural skin oil from the chin to make the needle glide smoothly. - Reusing Old Tatami (07:14)
When the underside is still in good condition, the old cover can be flipped and reused — a technique called “Kaeshi” (returning).
Tatami Core and Lifespan
The video features a 40-year-old tatami-doko — proof that well-maintained tatami can last for decades.
As long as there are no issues with mold or insects, the core can be reused for many years.
However, in humid climates or coastal areas, synthetic tatami such as those made by Daiken or Sekisui are recommended to prevent mold.
Typically, a re-covered tatami lasts about 15 years, but for standard households, 5–7 years is ideal for replacement.
Japanese vs. Chinese Igusa (Rush Grass)
Higuchi also explains the clear differences between Japanese and Chinese igusa — the rush grass used in tatami mats.
- Smell (02:40)
Chinese igusa tends to have a strong, sour smell that remains even when wrapped in deodorizing sheets. - Drying Process (12:19–12:36)
Japanese igusa is slowly air-dried, while Chinese igusa is dried rapidly using coal heat.
The burning coal leaves a residual smell, explaining the distinct difference in aroma.
These subtle differences make Japanese tatami not just a flooring material, but an expression of natural craftsmanship and cultural heritage.
Sharing Tatami with the World
Mr. Higuchi believes that tatami represents more than tradition — it is a symbol of harmony, simplicity, and respect for nature.
He has already shipped tatami to Australia, the Netherlands, and Mexico, and continues to develop new products for global lifestyles, such as:
- Foldable Tatami Mattresses – easy to ship and store
- Lightweight Tatami Mats – designed for modern homes overseas
All inquiries and purchase information can be found in the video descriptions.
Support the Craft
Both videos beautifully capture the heart of Japanese monozukuri — the spirit of creating with devotion and respect.
If you enjoy the videos, please support by giving them a thumbs-up, comment, or share.
