The Idea Lab


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How is a Backpack made

The first step is Design to determine the features. 

Is it going to hold a water bottle?

Do you want to have zippers or not?

Is there an inner pocket for a notebook or iPad?

Do you need a separate waterproof pocket to protect certain things from the elements?

A single strap or two straps?

The next step is to try and draw the backpack from different dimensions to realise the ideas. 

Consider using different colours to illustrate different materials 

Try and draw it in such a way that you can visualise its construction. 

Make initial guesstimates regarding the dimensions. 

Creating a pattern. For this you or the designer will need:

  1. A large roll of grid paper.
  2. Scissors (Rotary Cutter Better)
  3. Several Markers / Pencils of different colours. 
  4. Triangle
  5. Large ruler
  6. Ruled Cutting Mat



Ensure your pattern is accurate with crisp corners and edges. Use even curves and mark your pattern clearly. It can be easy to confuse your pattern pieces when all you have in front of you is empty  blank pieces of paper. 

Prototyping & Editing your pattern. With large scale manufacturing this is the most vital and important part of the manufacturing process. It's both time consuming and potentially a little costly, but it will serve to highlight any potential errors in your design. If you have already a design, but need help prototyping, now is the time to reach out to us. We can complete most prototypes within seven working days at a reasonable cost, highlighting the potential pitfalls in your product based on our experience in this industry. A prototype also allows you to test your product and see the real life aesthetics. For example you may not like your design once you turn it into something you can touch and hold.

Cutting Fabric. 

Be sure to spread your fabric out on a large flat surface, the wrong side up. Ensure it isn't double layered. 

Lay out the material to find the most efficient use of the materials and use a chalk or light pen to trace around the edges. 

Ideally use a ruler if cutting with a rotary cutter to ensure it is all done in straight lines. 

Be sure to cut out all the required pieces, including back pieces, padding and straps. 

Sewing Pockets, Sides and Straps. 

Start by first sewing pockets. Use a basting stitch (a loose stitch used to tack pieces of fabric together. A basting stitch is not structural so there is no need to knot the ends. Use velcro and binding tape to create durability and finish the edges. 

Repeat the above step for all of the individual components in your sketch, using binding tape, stitching and velcro where needed. 

Finally once all pockets, inner pockets, straps are attached according to your drawing it is time to fix the uneven top edges and ensure that your backpack is as well polished as possible. This can be done by adding binding tape to the outside edges. 

When a bag moves to mass production, each labour process or pocket will be undertaken by a person on the production line. It is very rare that one person will be responsible for more than one task. So if you are trying to save money on the finalised cost of your product, considering removing a pocket or an inner pocket somewhere. 

If you have a design or an idea for a backpack then feel free to hit the "Enquire Here" button below to get started.