The Process of Making Carpets
Carpet making in the 21st century is a combination of traditional
craftsmanship and state-of-the-art technology. Whether made by hand as has been
the case for centuries or with the aid of sophisticated machines, carpets are
formed either by weaving or tufting. The same principles of fiber manipulation
are involved.
Carpet weaving involves entwining yarn with itself. Vertical fiber filaments
called warps are locked into place with horizontal threads called wefts. The
durable and expensive woolen carpet is a prime example of this process.
Intricately patterned woven carpets can be made using yarns of various colors.
Tufting, or the bunching together of fiber into clumps, can now conveniently be
done by machines that work on computerized patterns of various densities and
construction. These machines eliminate imprecise manual procedures and mental
guess work.
The carpets are dyed after the fibers are locked into place. Numerous colors and
coloring methods result in countless design patterns or effects. Cut pile
carpets are stretched in the final stages of production before the top of the
pile loops are finally lopped off. This stage has great bearing on the softness
and feel of the carpet.
A secondary stretch is applied to the carpet’s backing to make it both stable
and elastic for installation. The way carpets are made greatly influences how
they are to be mounted on floors. Stain-proofing of carpets is another procedure
that is increasingly being made part of the manufacturing process.
One other assembly line procedure worth mentioning is the heat-setting and
twisting of continuous fibers beforehand to produce taught fibers that are
characteristic of frieze carpets. The resulting bulky yarn will retain its shape
over the long haul, making frequent carpet replacement unnecessary.
High technology and advanced machinery are dramatically changing the way carpets
are made. Tedious manual processes are being eliminated, and production in large
quantities over short periods are now commonplace. While these developments have
pushed the great art of hand weaving closer to becoming history, it has also
made possible the emergence of an ever-widening array of colors, textures and
designs. |
