How Carpet Is Made

The carpet that is made today is a mix of old world craftsmanship and a touch of 21st century innovation. By combining the two, carpet is able to become the household feature that we all know and love.

Manufacturing Methods

Carpet can be manufactured in two ways: weaving or tufting. Carpets that are woven are primarily wool and are very durable, and very expensive as well. The woven carpet types can be hand produced, as it has been for centuries, or by machine.

The continuous fibres may be heat set and twisted at the mill to give a tightly twisted product that is commonly found with frieze carpets. This type of yarn is less bulky although it will hold its shape for a long period of time, which is ideal for those who don't want to replace their carpet every couple of years.

Weaving and Tufting Process

In both weaving and tufting, the yarn for the carpet is woven through or approximately vertical fibres known as warps, and then locked into location with horizontal strands known as wefts. The woven carpets can utilise a variety of colours to create intricate patterns in the highest quality of carpets. Tufting machines use computers to determine the patterns, styles, construction and density.

Once the fibres have been locked into place, the carpet is dyed using a variety of methods that will create patterns or effects.

Stretching

For cut pile carpets, the final stage is stretched, cutting the pile loops. This is an important stage, as it will determine the softness and feel of the carpet.

The carpet will also receive a secondary stretch backing as well to give it stability and allow it to be stretched during the installation process.