Keeping the sturdy honnui (fully hand-sewn) construction of traditional zabuton cushions intact, we've created a honnui "kozabu" cushion that also fits beautifully into sofa-based living.

Honpindo is known for crafting amulet pouches and zabuton (floor cushions) using a technique adapted from Edo katazome (a traditional resist-dyeing method). The honnui kozabuton we carry at ZUTTO are about two sizes smaller than what most people picture when they think of a zabuton, giving them an endearing charm similar to a cushion or a chair back cushion.

This time, we asked Honpindo to create a special order based on that honnui kozabuton, modified according to ZUTTO's vision of what makes something "easy to use."

Why we requested a special order that would change the image of "zabuton = a Japanese-style item."

Honpindo proposes small zabuton that combine traditional patterns with the equally traditional honnui construction method. Rather than being an inaccessible piece of traditional craftsmanship, the honnui kozabuton has been reimagined as an everyday tool for daily life, and it has found its way into the hands of many customers since we began selling it at ZUTTO.

△The original katazome honnui kozabuton that served as the base

At the same time, we felt that in modern life—where flooring plus sofas and chairs have largely replaced tatami mats—transforming the Japanese-style feel of the kozabuton into more of a Western-style aesthetic could make it even more practical. We wanted something that could sit naturally on a sofa like a cushion, work as a back cushion for a chair, and of course still function as a zabuton for sitting on the floor.

We also hoped to preserve the strengths of traditional honnui zabuton construction—namely, a method that allows for long-term use and maintenance.

When we shared this vision with Honpindo, they agreed to create a special-order honnui cushion approaching the challenge from both a design and manufacturing perspective.

Creating a special order that would be "a Western-style item that's easy to incorporate into daily life, yet still built using the honnui zabuton construction method" was a first-time challenge even for the craftspeople, who went through numerous prototypes.

They considered removing the "tassels on all four sides" that give the zabuton its Japanese-style impression, explored whether the protruding thread in the center could be limited to the back side only, and thought carefully about what shape would work best for use on a sofa. After much deliberation, they arrived at the [Honnui Kozabu Cushion] presented here.

How is the Honnui Kozabu Cushion made? A behind-the-scenes look at production

Wanting to see firsthand how the special-order Edo katazome honnui kozabu cushion is made, we visited a futon craftsman's workshop.

Mr. Nakamura is a futon craftsman with over 50 years of experience in this trade. He explained that the process for making cotton futon and zabuton is fundamentally the same, and he makes both. With his gentle smile, he perfectly fit the image of a craftsman who has spent a lifetime working with cotton.

Do you know how cotton futon and zabuton are actually made? I have to admit, I didn't—I had assumed they were filled with fluffy, ball-like cotton, like a stuffed animal...

Here's the cotton padding that's used. Contrary to my expectations, what appeared wasn't fluffy loose cotton but sheets of it. Of course, being cotton, it's soft to the touch, but the layered, folded sheets have a surprisingly firm feel despite being cotton.

Cotton used for clothing generally has long, thin fibers, which are prized for their soft texture. But cotton used for futon and zabuton is the opposite—fibers that are "thick and short" are considered ideal. This is mainly because such fibers trap air, giving the padding a fuller feel while also making it more durable. Cotton closer to its unmodified, original species is said to be better suited for zabuton and cushions than cross-bred varieties. However, he told us that as more farmers cultivate cotton with longer fibers, it has become increasingly difficult to find the ideal cotton for zabuton in recent years.

Each sheet weighs about 300g, and the entire sheet is placed into the kozabuton.

The process goes as follows:

1. With the zabuton cover—already sewn on three sides—turned inside out, the sheet of cotton is placed on top.

2. The cotton is torn by hand to match the size of the cover.

3. Using the same method, additional layers of cotton are stacked on top.

4. The amount of cotton is adjusted so that the center of the cushion is thicker while the rest remains an even thickness—tearing off bits of cotton and adding them elsewhere as needed to level out the padding.

5. The bottom-most sheet of cotton is folded inward like origami, wrapping around everything else to enclose it.

6. Through the one open side of the cushion cover, the cotton is turned inside and worked into place as the cover is flipped right-side out.

7. The cotton inside is adjusted, with fine-tuning to ensure it reaches evenly into all four corners.

8. One side is sewn shut with silk thread, and the center "navel" point of the cushion is also stitched to hold the cotton padding in place.

We highly recommend watching the video to see Mr. Nakamura at work.

Every step of Mr. Nakamura's process flows smoothly and moves at remarkable speed. His efficient, fluid movements are mesmerizing to watch. Just as you notice the cotton sheets being layered, they're suddenly wrapped up like a crepe, their surface turned perfectly smooth. What follows—flipping the cover right-side out while packing the cotton inside in one motion—is a step that conveys real strength and skill.

Traditional honnui (properly hand-stitched) zabuton are made by stitching the fabric and the cotton batting inside together so that the cotton doesn't shift or bunch up as the cushion is used, and decorative tufts are created in the process. This is done at all four corners, and by adding a cross-shaped stitch in the center of the zabuton, the cushion is secured both at the corners and in the middle.

For this custom order from ZUTTO, we asked for a honnui kozabu cushion adjusted to suit modern lifestyles: the decorative tufts at the four corners were removed, and instead of a cross-shaped stitch in the center, we asked for a single straight stitch. In addition, we asked that the tuft in the center be placed only on the back side. "Since this is smaller than a regular zabuton, a single stitch in the center should be fine," said Nakamura-san.

Laughing, he said, "I've never made a zabuton like this before," but he carried out the work with great care.

Enjoying a Western-inspired design based on a komon pattern

During the planning stage, when we requested that the custom honnui kozabu cushion be adapted to suit lifestyles with flooring, sofas, and chairs, Ono-san of Honpindo kindly offered to help by creating a new design to match. As a textile designer, Ono-san's proposal was to give a traditional pattern a modern arrangement.

Here are the three designs that were created.

・Hana-komon: A classic pattern that has been used in various designs. The yellow center of the white cross-shaped flowers is the accent point.

・Kusabana-mon: Rather than a repeating pattern, this design has the presence of a single illustration.

・Mikuzushi: A motif made of arranged rectangular "sangi" tools used in traditional calculation. A simple design that evokes the refined taste (iki) of Edo. 

Honpindocreates its designs using a unique dyeing method that gives Edo katazome (traditional stencil dyeing) a modern arrangement.

The pattern is carved into a stencil paper with a small knife, and once the stencil has been applied to the cushion cover, the fabric is then steamed so that the color is removed exactly according to the stencil pattern. 

For designs that require color, each spot is colored in by hand with a brush.

By the way, we've been calling this the "kozabu cushion" for a while now—some of you may be wondering what "kozabu" means.

Kozabu is short for "kozabuton" (small zabuton). While we were exchanging messages about this custom order, Ono-san of Honpindo kept referring to it as "kozabu, kozabu," and when it came time to decide on the product name, we found ourselves wanting to include this term.

While we asked for the cushion elements to be emphasized, through our research we came to strongly feel that this is, after all, still a traditional Japanese zabuton, not simply a cushion—and this is another reason we decided to include "kozabu" in the product name. Sometimes a cushion, sometimes a small zabuton. Please feel free to incorporate it into your life however suits you.

On "uchinaoshi" (re-stuffing), for peace of mind and long-term use

There is a maintenance service for futon and zabuton called "uchinaoshi." This is a repair service performed by craftsmen when the cotton batting inside has become flattened or has shifted with use.

There is a fee, but the appeal lies in the peace of mind that comes from having the very craftsman who made the item also perform its maintenance. So what exactly does uchinaoshi involve?

1. First, at the Honpindo workshop, the cover is separated from the cotton batting, and the cover is washed. If any colored areas have faded, they are re-dyed.

2. The cover and cotton batting are then passed to Nakamura-san and a cotton specialist. The cotton batting is cleaned to remove dirt, and the cotton, which has become hard and flattened, is softened up again. It is weighed, and cotton is added if necessary.

3. Craftsman Nakamura-san then puts the cotton batting back into the cover and neatly re-stitches it.

Most people who request uchinaoshi for their Honpindo kozabuton have used them for about 5 years, but many are surprised by how clean and how plump the cotton feels after the re-stuffing.

Nakamura-san also had this to say:

"I've worked on all kinds of futon and zabuton over the years, but the fabric Honpindo uses for the covers—the Aizu momen—and the Indian cotton used for the batting are both really high quality. With proper maintenance, I think these could last around 10 years."

Edo katazome and honnui zabuton craftsmanship, together with high-quality Indian cotton.

Honpindo's honnui kozabuton are created by combining these three elements, which have now become quite rare. The concern that it may soon become impossible to make items of the same quality is, unfortunately, one of the factors that adds to their value. But rather than simply emphasizing that rarity, we wanted to convey the appeal of these cushions as "high-quality items thoughtfully made to last"—and that's why ZUTTO requested this custom honnui kozabu cushion.

We would be delighted if these cushions add color to your daily life simply by being there, offer comfort to your back or hips from time to time, and bring a warm feeling to your heart whenever you see them. 

▼[Custom Order] Honnui Kozabu Cushion — Click here for the product page