How to make a rug from scratch?

Rugs, more than simple decorative elements, are authentic works of art that require skill, patience, and a deep knowledge of ancestral techniques. Through this blog, you'll learn about the process of rug making.

Selection of Raw Materials

Have you ever wondered what material rugs are made of? As you'll see, there's a great variety, and before starting to make a rug, we must select the correct raw materials. Traditionally, natural fibers like wool, silk, cotton, and in some cases, linen, are used. However, today most rugs are made with synthetic fibers like polypropylene or polyester. The quality of the fiber is crucial, as it determines the durability, texture, and final appearance of the rug:

• Wool: Wool rugs are known for their durability and stain resistance; wool is one of the most used fibers. It comes mainly from sheep and, occasionally, from goats (like cashmere wool).
• Cotton: Generally used for the rug's base, cotton provides stability and structure.
• Natural fibers (Jute): Provides great durability and this material is very environmentally friendly. It is a fiber whose rough appearance contrasts with the softness it provides to the touch. It is perfect for hot climates where one often walks barefoot. Jute rugs have a rustic look, ideal for rural environments where colors and natural elements stand out.
• Synthetic fibers: These are acrylic, nylon, polypropylene, or polyester rugs, among other materials. Nylon is very common in rugs because it is very resistant to heat and dirt, making it ideal for high-traffic areas. Polypropylene is also very durable.

Carding and Spinning

Once the raw materials for the rug are selected, the fibers go through the carding process, where they are untangled and aligned to form a uniform mass. This carded fiber is then spun to create threads that will be used in the weaving of the rug.

Dyeing of Threads

Dyeing is a crucial stage that defines the colors and patterns of the rug. Natural dyes obtained from plants, minerals, and even insects are used. These natural dyes offer a palette of rich and durable colors. Currently, synthetic dyes are also used to obtain a wider range of colors and greater uniformity.

Design and Pattern

The rug's design can vary from simple geometric motifs to complex floral representations and pictorial scenes. Designers create detailed sketches, which are then translated into a pattern that will guide the weavers.

Weaving

Weaving is the heart of the rug-making process. There are several weaving methods, but the most common are tufting or machine weaving.

• Tufting: Tufting is a widely used technique in rug manufacturing. The concept "tufting" or "tufted" comes from the English "tuft." In tufting processes, the fibers of the rug's pile layer are inserted into a prefabricated backing material. To fix the knots of the pile layer into the backing material, the raw material's backside has a coating composed mainly of latex or polyurethane.
• Weaving: In the weaving process, the warps (set of threads placed parallel to each other on the loom to form a fabric) are divided and, using the corresponding devices, some of them are lowered and others are raised. This creates a space between the warps. Through this space, the shuttle slides and inserts the wefts. These alternating ups and downs place the warps above or below the wefts, meaning the threads interlace, which is called "binding."
• Hand-knotting: This method is the most traditional and valuable. Each knot is made by hand, and the knot density (measured in knots per square inch) is an indicator of the rug's quality. Rugs like Persian and Oriental rugs are created using this method, resulting in unique and durable pieces.

 Finishing

Once woven, the finishing is done, which includes trimming loose threads, reinforcing the edges, and, in some cases, applying a coating to increase durability.

Inspection and Quality

Before reaching the final consumer, each rug undergoes a rigorous quality inspection. The uniformity of the weave, color consistency, and absence of defects are reviewed in detail. Only rugs that meet the highest standards are approved for sale.

The creation of a rug is a meticulous process that combines tradition, art, and technology. Each stage contributes to creating a unique piece that not only beautifies the space where it is placed but also tells a story of skill and dedication. When acquiring a rug, you are not just buying a decorative object, but a true work of art.