Designer Rugs: Custom Inlay Fabrication
or Tufted Wool?
Have 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.
For 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 industrialized
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.
Let's take a closer
look at the more advanced methods of these two
rug making techniques:
Technique#1- Tufted Wool Rug Production.
After 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.
Finally 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 Pros -
1. The high quality attractive
appearance and durability.
2. The versatility of design
- easier to integrate complex designs into the
production process. Other yarns can be introduced,
like Silk.
3. The appeal of using natural
fibers.
The Cons -
1. Costs are higher. Materials
are generally 100-300% higher than nylons.
2. Production times are generally
12 weeks and often much longer.
3. Most production facilities
are overseas.
Technique #2 - Custom Rug Fabrication
using advanced generation Nylon Fibers:
Custom 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'.
Each 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 for cleanability.
A 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.
Pros -
1. High quality attractive
appearance and durability
2. Attractive and affordable
price points for a wide range of designs
3. Quick production times at
4-6 weeks.
4. Can be produced with pre-tufted
nylon or wool.
5. Produced in the United States.
Cons -
1. Difficult to produce complex
designs at affordable price points.
2. Some carpet styles are limited
in color ranges.
3. Carpet mills frequently
make changes in carpet styles. When your
favorite style is suddenly discontinued, you have
to find alternatives.
We've 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.
Either 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
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