Production Steps of Hand made carpets
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Production Steps of Hand made carpets, hand made carpet manufacturing process, production steps
Designing / Mapping
The first step in making a custom rug, whether it is hand knotted or hand tufted, is preparing the design map. This is a crucial step, as it will determine the final outcome quality. Our expert designers spend as much time as necessary making sure their map is perfect. We can do it by hand or per computer, depending on the type of design and the final effect desired by the customer. With hand knotted rugs we usually draw our design maps with the help of computer software in which we can specify each knot and make sure it is the way our customer wants to have it. The resulting CAD will create a weaving graph for our weavers to follow later.
Dyeing The Yarn / Colour Matching
This is how we select the colours for the varied yarn that we offer for our custom rugs and how we dye them. Whether you choose to have your rug handmade in linen, bamboo silk, hemp, and nettle or recycled PET, at Rug Your Life you can always choose the colours you want for your rug. When we receive your design and colour preferences, if different than the colours on the design, we start looking for the closest possible matches in our Pantone and ARS colour guides.
Weaving
The design is then woven following the design map or weaving graph. Often several skilled weavers will sit and work together on the rug at the same time. The rug is created by carefully knotting the right color on the right spot on the warp. The weavers move their hands very precisely and quickly, while paying close attention to each knot’s color. Here is a short video of one of our weavers creating an elaborate custom hand knotted rug. And here is another video of the weaving
Clipping
the yarn needs to be cut at the right length and details as Clipping / carving or embossing are applied.
Washing
Once the carpet is completely woven, it comes off the loom and goes through a soft, but vigorous washing process with water and neutral detergents. This process removes dust and small yarn pieces. It will leave the carpet completely clean and it is important to maintain and care for the carpet by vacuum cleaning it regularly once you have it.
Stretching
After washing, the carpet is stretched in order to balance the handmade knots and create a perfectly flat-laying surface. This is the best way for the rug to dry and get its final shape and exact size.
Binding
You can choose whether you want to keep the fringe of your custom hand knotted carpet or if you prefer it bound. The binding is done either in one of the design colours, in a completely different one, or following the design colours all around for a continuous pattern. In any case, it is always our binding master who very skillfully creates the perfect frame for your rug.
Finishing
Once All Process is done. Carpet goes for QC (quality Check) and Then inspection is done for colour matching, Design Matching and Weaving Quality, Colour fastness, when everything goes good, later forwarded for next step that is packing.
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Production Steps of Hand made carpets, hand made carpet manufacturing process, production steps
Production Steps of Hand made carpets, hand made carpet manufacturing process, production steps