area rugs

Tufted Rug Construction

I love it when my worlds collide, with a background in product design and having my own decorating business I am fascinated to learn how the products we buy and love are made. Last week I attended a seminar presented by Delos Rugs at J&S Designer Flooring and was so excited to learn more about their rug construction. With different construction methods, materials, and styles the options are seemingly endless, so in this post I will focus on how tufted rugs are made. I think it's hard to visual the process so I've included lots of video to demonstrate how it works! Have fun looking around!


Design Phase 1: image source Delos Rugs

Color Selection Phase 2: image source Delos Rugs

To Begin

There are many steps involved before you can actually begin creating the rug, such as design, color selection, pattern transfer, and many more. Once you get to the tufting stage you create the rug by pushing the yarn through a fabric backing with a tufting gun, like this image shown below. Here are the key steps in the tufting process from CRI (Carpet & Rug Institute)

  • Yarn comes from cones on creel racks (or from big spools called beams) into the machine.
  • The primary backing feeds into the machine.
  • Yarn and primary backing come together in the machine (full shot of machine)
  • Yarn is fed through needles on a needlebar of a tufting machine. Needles repeatedly penetrate or tuft into the primary backing.
  • The tufted carpet is mended and inspected.
  • Carpet is rolled onto large rolls for the next step (whether it’s to be dyed or to be backed.)

(image source)

Types of Tufting

There are also several ways a tufted rug can be made:

- Hand tufting with handheld gun

- Hand tufting with automatic gun

- Machine tufting

 

Finishing

There are many steps involved in finishing a rug, and most depend on the style and design. In order to keep the yarn in place, all tufted rugs have a layer of latex that is painted or sprayed on the back which serves as glue. Then a piece of fabric is laid on top which covers the latex and the generally messy looking back from the tufting process. That's actually one way you can tell if a rug has been tufted is if it's covered on the back. 

(image source)

It sheds from shearing...

The face pile of a tufted rug needs to go through some finishing steps, which include shearing to create a flush uniform surface. Depending on the design the yarn fibers are color sorted by hand to keep the pattern clean and defined. Sometimes the edges are even carved for a more dimensional look. The first video is a bit dated but it shows all the steps concisely: latex, shear, carving. 

This second video shows an alternative carving tool. 

 

The End...

Well actually that's only a small fraction of one type of rug construction but I hope you enjoyed these videos as much as I have! It's great to learn and gain a better understanding of what goes into a tufted rug so you can see the value of what you are buying and be an informed consumer!

Cheers, 

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Inspired by the things we Love

Valentines' day is almost upon us and love (and lots more snow) are in the air. Love drives us in many ways in both our personal and professional lives. For me design has always been something I've enjoyed, and it seems the more I learn about it the more I find to love. Materials and products are always changing with trends and technology so it keeps the industry fresh with lots to learn - it seems almost infinite! (just search the term "ICFF" in my blog sidebar!)

As a member of the Interior Redecorators Network I strive to learn and grow each year so I can provide my clients with the best service I can. Within the IRN there are different levels of membership based on credits you can earn from things like participation, education, and community involvement. And I am proud to say that I recently earned a Gold Member status! You can see my new shiny pin above :)

 

I am also getting a head start on maintaining my Gold Membership by attending more classes. I was at a CEU yesterday called "Area Rug Construction & Terminology" held at J&S Designer Flooring. First of all their showroom is amazing, has a wide selection of products, and the associates are so lovely and helpful. Then the presentation by Delos was so extremely informative and helpful, they explained how rugs are made and passed around beautiful samples to demonstrate. Rugs are something we all live with and might even take for granted, but once you start learning about them it's easy to see how it's a world in its own right! I am so excited to share some of what I learned so I hope to do a post about it next week.

Inspired by the things (or pets) we love....

Then there is the "occupational hazard" aspect of going to a fantastic showroom.... of course I always look for client projects but this was the first sample I brought home as a stair runner contender for our house! I am noticing a certain "colorway" that I'm drawn too... it has to do with one certain fuzzy animal that I love. Isn't it funny how I'm drawn to the subtle color variations of tans, cremes, with golden bronze hightlights? Let's take a look closer here... 

Just look at that edging along his ear... 

And that fuzzy butt, the tip of tail has that same coloring. 

He's a happy pup - isn't he so fuzzy?! And so white with bronze accents? We love him to pieces, and apparently I am taking color cues for my home from him ;) 

Now take a look around your home - what has been inspiring you lately? Any particular product, pet, or person? Anything that you pass in your daily journey you've been thinking about? I would love to know - we are all victims of love whether we realize it or not ;) 

Happy Valentines Day
with love, 

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Pantone Products

I've been reading a lot about color lately and was excited to see the most recent catalog from The Home Decorators Collection featuring four new lines of rugs that are part of Pantone Universe! There is Pantone focus, Pantone expressions, Pantone prismatic, and Pantone matrix.

This first picture from their catalog that shows a simple shag in the Pantone 2013 color of the year, of course: Emerald.  One of the other colors available is Tangerine Tango which was 2012's color of the year. These are basic color block options for a dose of saturated color in any room.

This catalog page shows their more subtle color combinations which all have a soft feathered edge to the patterns. I really like the one they picked to photograph above, called New Antique. You'll also see they've selected a few Pantone chips on each page so you can "perfectly match your wall color, laminates, furniture, accessories and more with our rugs."

 

I also liked these tone on tone geometeric wool flatweaves shown above. 
Horizon Blue: Pantone 19-4057 TPX and Pink Flambe 19-3138 TPX