Custom Inlay Fabrication or Tufted Wool?
by Russell Webb
you ever wondered about how those beautiful designer rugs are created
and produced? Here is a close up look into the two uniquely different
techniques of custom rug building.
centuries the only high quality rugs available were produced from
wool and silk yarns. This was, and in some countries still is, all
woven and tufted by hand. In industrialed nations these production
methods have evolved. Now manufacturers are using advanced tufting
guns that rapidy inject the yarn into the backing. This backing
acts as a foundation that holds the yarns in place.
take a closer look at some of the more advanced methods of tufted
wool rug production.
a design is chosen, the design template is carefully transferred
onto the backing. The Backing is mounted within a frame that is
vertically positioned. The yarn colors are then tufted with handheld
tufting guns. Imagine large spools of different color threads feeding
into the guns. All of the various colors are patiently integrated
to create the final product.
there is a shearing process that shears the face loops to create
a smooth finish. Often there will be a blend of cut and loop piles
creating an attractive contrast and texture.
The high quality attractive appearance and durability.
The versatility of design - easier to integrate complex designs
into the production process. Other yarns can be introduced, like
The appeal of using natural fibers.
Costs are higher. Materials are generally 100-300% higher than nylons.
Production times are generally 12 weeks and often much longer.
Most production facilities are overseas.
Custom Rug Fabrication using advanced generation Nylons
fabricated rugs are produced in a different way. In the U.S., the
avalability of nylon carpet is abundant. This availabilty has created
another technique of rugmaking called 'Custom Inlay Fabrication.
day carpet mills all across the US produce large rolls of tufted
carpets in a variety of styles and colors, this is the typical carpet
found in all carpet stores. A carpet dealer can order these pre-tufted
carpets by the roll, or in smaller quantities. The quality of these
nylon yarn systems now parallels, and some would argue that they
surpass the traditional wool yarns, for durability and certainly
rug fabricator then orders the various colors that are needed. A
template of the design is carefully created. The design elements
are then cut and inlaid into the main field piece, like a puzzle.
These rugs are produced on tables.
There is a second phase of this fabrication process called 'sculpture'
or carving. This is a process of shearing and beveling the design
details. If done properly this can elevate the rugmaking process
to the elite status preferred by decorators and designers.
High quality attractive appearance and durability
Attractive and affordable price points for a wide range of designs
Quick production times at 4-6 weeks.
Can be produced with pre-tufted nylon or wool.
Produced in the United States.
Difficult to produce complex designs at affordable price points.
Some carpet styles are limited in color ranges.
Carpet mills frequently make changes in carpet styles. When your
favorite style is suddenly discontinued, you have to find alternatives.
just examined the difference between the two major techniques for
custom rug manufacturing. Both methods offer an excellent finished
product. The natural fiber, tufted wool products will always cost
more and in general take longer to produce. The nylon fabricated
products have a broader market appeal due to affordability and quicker
production times. Wool carpet can be fabricated as well.
direction you choose, you should end up with a gorgeous customized
home interior that reflects your unique personality and character.
Have fun with it!
© 2007 Russell Webb
TO USE THIS ARTICLE? You are welcome to use it, as long as you include
the following: Russell Webb, your friendly
expert Custom Carpet Maker. If you're ready to discover the creative
and exciting world of custom carpet sculpture, and have fun doing
it, then why not request a quote at http://www.custom-area-rugs.com