How Our Bags Are Made — Step by Step | AYS Bags
How Our Bags Are Made — Step by Step
Every AYS bag is the result of a deliberate, multi-stage process. Here’s what goes into yours.
Step 1: Leather Selection
It begins with the hide. Every batch of leather is inspected for grain quality, temper, colour consistency, and edge integrity before it enters our production process. Only hides that meet our full-grain or top-grain standard are approved.
Step 2: Pattern Cutting
Our patterns are precision-cut to minimize waste while maximizing the use of the strongest sections of each hide. The outer shell, lining panels, straps, and pockets are each cut to exact tolerances — because imprecise cuts compromise the finished seam.
Step 3: Edge Finishing
Raw leather edges are bevelled, burnished, and sealed before assembly. This step is often skipped in mass production — but it’s what prevents fraying and gives AYS bags their clean, finished look even years later.
Step 4: Stitching
We use a reinforced saddle stitch on all load-bearing seams. Unlike machine lock-stitching, saddle stitching will not unravel if a single thread breaks — making it the gold standard in leather goods construction. Thread tension and stitch density are checked throughout.
Step 5: Hardware Setting
Zippers, clasps, D-rings, and rivets are set by hand. We use only tarnish-resistant, solid hardware — no hollow or plated components that will pit or corrode with daily use. Each piece is tested for smooth operation before moving forward.
Step 6: Lining & Interior Build
Interior pockets, card slots, and key hooks are assembled and attached to the lining before it is married to the outer shell. The lining is chosen to complement the exterior — durable, smooth, and easy to wipe clean.
Step 7: Final Inspection
Every finished bag is inspected against a checklist of over 20 quality points before it is approved for packaging. Stitch consistency, hardware function, lining alignment, strap integrity, and overall symmetry are all verified. If it doesn’t pass, it doesn’t ship.