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What type of seam is best for a beanbag?

Flat Felled Seams are Stronger and Last Longer. A good quality beanbag is put together with a genuine flat-felled seam with lockstitch sewing, like that of a household sewing machine. A flat-felled seam is the sturdy, hardwearing, long-lasting seam found on denim jeans and coveralls. All the raw edges that are prone to fraying are protected by a double fold that is interlocked and hidden away within the seam, not merely turned inside within the product. This interlocking of the fabric strengthens the seam because the tension is on the folds of the fabric instead of the thread.

Then the seams are secured with a lockstitch. This means the seam will not unravel if a single thread breaks. Each and every stitch has to be picked and cut to take apart a lockstitch seam.

Some beanbags utilize a simulated flat-felled seam that doesn’t actually secure four layers of fabric, doesn’t use the strength of the fabric, and uses a chain stitch that can easily unravel. The chain stitch was designed to move in the seams of double-knit clothing for comfort and a relaxed fit. It was never designed for unyielding fabric like vinyl, or for applications that demand durability like furniture. Every time you sit in a beanbag with a chain stitch, the thread moves through the needle holes and saws the material, like ripping the perforation on the top of a bag of dog food. A chain-stitched beanbag is almost guaranteed to wear poorly and rip along the seams.