Knowledge

TUFTING

1000 – 2000 rows of pile yarn are simultaneously stitched through carrier fabric (woven or nonwoven primary backing)

· Most popular method for carpet manufacture (> 90%)

· Variety of textures achieved with varying colours, pile height variation , using various types of yarn etc.

Cut pile

Carpet pile surface with all of the yarn tufts of the same height

· Patterned effects created using different yarn colours

· Geometric designs created with shifting needle bar attachment

Loop pile

· Level loop

· Multilevel loop

· All loops of same height from row to row

· A patterning attachment which varies yarn tension is used to achieve different pile heights in a pattern repeat

Cut and Loop

· A combination of cut and loop pile

· Varying levels of pile height and pile textures create interest

WEAVING

Coloured pile yarns and backing yarns woven simultaneously to form finished product

· Most often used in commercial locations

· Heavy, firm hand, high durability

Wilton

· Carpet made on Wilton (or wire) loom

· Loop (Brussels) or cut pile

· Level surface or multilevel

· Capable of intricate patterning, styling and colouration versatility

· Withstands intense traffic so mostly used in busy commercial locations, also rugs

· Durable, dense, bends all ways

Face-to-face

· Two carpets woven simultaneously, then separated

· The fastest method of weaving a carpet

Axminster

· Carpet made on Axminster loom (3 types)

· Cut pile only, mostly single level

· Offers wide range of colours and designs

· Withstands heavy traffic

· Durable, ends only in one direction

KNITTING

Warp-knitted yarn fabricated on face and back simultaneously. Pile, backing and stitching yarns are looped together by three sets of needles

· Similar to woven carpet but less stiff

· Mostly solid colours

· Quality depends on amount of pile yarn and strength of attachment of the face, chain and backing yarns

NEEDLEPUNCHING

Web of fibres moves through machine. Barbed felting needles penetrate and entangle fibres into durable felt-like fabrics

· Usually made from solution-dyed polypropylene

· Diverse range of designs

· Only used in glue-down situations

BONDING

Yarns are implanted into vinyl or thermoplastic coated backing

· Often dye-cut for modules (tiles)

· Cut-pile produced by slitting two parallel sheets of face-to-face carpet