In order to manufacture Sudare, we first finely cut round bamboo to make sticks.
One of the great features of Manyo texture is an aligning technique for bamboo nodes called ‘Hushi-zoroé’. This technique consists of remaining the nodes of bamboo, in order to create vertical waving patterns on the texture. This waving pattern is thus natural and luxurious.
Generally the bamboo nodes are shaved off in Shikisai and other general Sudare. For this reason, all the cross-cut sections of the bamboo sticks are round.
In order to collect only bamboo with nodes, after having cut the bamboo inside and outside (with the nodes, i.e., the bark side), we select only the outside ones.
In addition, we select the bamboos sticks which have a similar distance between a node and a next one, and have a similar color. We have to collect at least 1,000 such bamboo sticks, to create Manyo texture with a height of 180 cm. So considerable time and effort is required to manufacture Manyo.
We insert manually each stick (weft) into the loom, and shifting the other subtly, to complete the vertical waving pattern “Hushi-zoroé”.
That’s why we use a weaving loom called “Ashibumi-shokki.” This weaving technique is called “Nejiri-ami” and is used only in Japan. The “Nejiri-Ami” technique requires more manpower than ordinary looms, because we must insert bamboo sticks manually.
Thus, the production capacity of Manyo’s texture is naturally limited and more expensive than normal Sudare.