According to Statista, more than 51% of homes in the US have carpets, with this figure expected to grow by 5.6% yearly between 2023-2028. This is an impressive figure! But, have you ever wondered what carpets are made of and how they’re made?
Carpets are made of natural and synthetic fibers, with the latter being the more popular ones. Among the materials carpets are made of are nylon, polyester, polypropylene, wool, cotton, seagrass, sisal, jute, silk, and blends of different materials.
Knowing the type of materials used to make carpets in terms of their advantages, disadvantages, care, longevity, and other aspects is important in choosing the best carpet for yourself. You will also learn how carpets are made and how to best care for the one you choose.
What is a carpet made of?
As a flooring option, carpets are favored for their ease of cleaning, temperature control, comfort, longevity, and flexibility. You can even add heating to carpets for a warm house. The fabric also helps cover refinished wood floors, protecting them in the process.
The main materials for carpets include the following:
1. Nylon
Nylon, a popular synthetic fiber, is durable and highly resilient. It resists fading and staining and also withstands heavy foot traffic. You can find nylon carpets in a wide range of colors and styles.
2. Polyester
Polyester is another synthetic fiber (like nylon) that is used in carpet production. It’s a stain-resistant fiber with a soft and luxurious feel. It’s not, however, as durable as nylon.
3. Polypropylene (olefin)
Polypropylene is used for both indoor and outdoor carpets due to its high resistance to mold, mildew, and moisture. While less durable than nylon, it’s more affordable, hence a popular carpet material.
4. Wool
Being a natural fiber, wool is more expensive than synthetic alternatives. Wool has a luxurious texture, and it’s also durable.
What sets it apart is its high level of flame retardance and stain resistance. It’s a great option for heated floors.
5. Seagrass, Jute, and Sisal
These are natural plant fibers that create unique textured and rustic looks. Although not as soft as cotton, they are still favored for their contribution to the aesthetics of a house.
6. Cotton
Cotton is a natural fiber favored for making lower-pile carpets and area rugs. Its main downsides are its low durability and ease of staining. You should thus not use it where there’s high foot traffic.
7. Silk
Silk is one of the most luxurious natural fibers for carpets. It’s soft and used in high-end settings. However, it’s delicate and requires careful maintenance.
8. Blends
Some carpets blend various materials to combine the benefits of the materials used. For example, wool and nylon are combined to have soft and durable carpets.
For my floors, I have always leaned towards synthetic fibers, especially nylon. They’re easy to clean, durable, and can be found in many different styles and colors to fit any room you want. They also work great with different types of floors.
How are carpets made?
Carpets are made through various procedures, although the process begins with the selection of the fibers to the dyeing and finishing. Knowing this helps in choosing the best carpet for your needs since the manufacturing process determines the durability of your carpet.
The main procedure of how carpets are made is as follows:
1. Fiber selection
First, the fibers or fiber combination is selected to create the carpet. This determines the texture, durability, and other aspects of the carpet.
2. Fiber preparation
The fibers chosen may need to be dyed or treated to achieve certain colors and properties. The processes used include solution dyeing, adding color to the fiber before forming a yarn.
3. Yarn formation
After that, the fibers are spun into yarn through various methods, such as twisting the fibers together to form continuous strands.
4. Backing material
The backing material, which will serve as the base of the carpet, is then prepared from various materials such as polypropylene, woven fabric, and others.
5. Tufting or weaving
Tufting and weaving are the two main methods used to make the surface (pile) of the carpet.
- Tufting: tufting involves feeding the yarn through needles on a tufting machine. The needles then loop the yarn through the backing material to create the surface of the carpet. The loops can be left intact (for loop pile carpets) or cut to create cut pile carpets.
- Weaving: the yarn is woven through the backing material with a loom to create a more intricate and tightly woven surface. Wilton and Axminster are some examples of woven carpets.
6. Backing application
After weaving or tufting, a layer of latex adhesive is then added to the back of the carpet to secure the fibers and provide stability.
7. Finishing
After applying the backing, the carpet is then sheared to attain a uniform pile height and appearance. Designs and patterns can also be carved into the carpet in this stage.
8. Dyeing and finishing (optional)
The carpet’s texture, color, and properties can be further enhanced through additional dyeing and finishing to attain the desired finish. Soil and stain-resistant treatments can also be added at this stage.
9. Quality control
The next step is the carpet inspection for inconsistencies and defects. Only after this stage can the carpet move on to the packaging and distribution stages.
10. Rolling and packaging
The finished carpets are then rolled onto large rolls, cut into the required lengths, then packaged for shipping.
Types of carpets
The main types of carpets you can pick from include the following:
1. Woven
Woven carpets are produced on a loom (just like woven fabric) through the process of weaving. The process allows for the creation of intricate patterns incapable of most other methods. The resulting carpets are the most expensive, given the slow process of manufacturing.
2. Knotted
Initially called supplementary weft cut-loop pile carpets, knotted carpets are made through a process whereby the structural weft thread alternates with a supplementary weft that rises at right angles to the weave’s surface.
These carpets can also be woven on a loom, with symmetrical and asymmetrical knotting being the main types of knotting.
3. Needle felt
The needle-felt process produces the most durable carpets suited to areas with high foot traffic. Synthetic fibers are felted and intermingled with forked and barbed needles to form the carpet.
4. Tufted
Tufting is the most common method for making domestic carpets in most homes around the world. The process involves injecting the pile with a tufting gun into a backing material which is then bonded to a secondary backing.
The pile is sheared afterward to attain the desired look and size of the carpet. This way, you can get a large carpet for an open floor plan without spending too much on it.
5. Other types
Besides the types and methods above, other carpet types include flatwoven, hooked rugs, and embroidered carpets. These are formed through methods that may differ from the major ones or combine the above methods.