How are rugs actually made?

Knotting, weaving, tufting (say what?!), needles: each one a unique weaving technique used in rug production. Although the names sound quite simple, the reality is the opposite. What do the different weaving techniques involve and how are they applied?

Rug tufting

Let's start with a term you've probably never really heard of before: tufting. This weaving technique is used to produce high-pile rugs in all sorts of shapes and sizes. Those soft bathroom mats in the shower room? There's a good chance they've been 'tufted'. The local football club's artificial grass pitch? Probably 'tufted'.

The technique was developed in the 1950s in the United States and is derived from how sewing machines work, only on a much larger scale. In metre-long machines, dozens of needles are embedded that push yarn through the rugs. This creates loops that can be shaped into a low-pile vintage rug. The loops can be cut open to create soft, high or low piles. By playing with heights, yarns and colours, various patterns can be created. For real precision work, tufting can also be done by hand.

Weaving rugs

Weaving a rug takes a bit longer than tufting. It's certainly no less beautiful! Weaving a rug is an age-old technique that has continued to improve over the years. The basis of rug weaving is actually very simple: it's all about interlocking threads by placing them horizontally and vertically through each other. The vertical 'warp' threads are stretched and consist of a series of chain threads. At right angles to these, the horizontal 'weft' threads are woven through the warp. Because the foundation of this technique is so straightforward, it can be applied to all kinds of materials such as wool, silk and cotton. From this basis, there are many methods by which diverse patterns can be woven.

The beauty of the weaving technique is its authentic character. Weaving a rug is a true craft that is passed down from generation to generation. Creating patterns by varying with the warp and/or weft threads is precision work that is often done by hand. Only then do the unique, stunning patterns in woven rugs come about, making them so beautiful. The weaving technique originated in regions around the Middle East, where the most magnificent creations have been woven for centuries. The technique came west in the 19th century when demand explicitly increased. To meet this demand, yarns were increasingly machine-woven. To this day, alongside machine-woven woven carpets, you'll find countless hand-woven rugs from all around the world.

Knotting rugs

Knotting rugs is an exceptional form of craftsmanship. The technique is extremely labour-intensive, which results in a beautiful end product! As with weaving, the weft and warp threads form the basis for the technique. After each weft thread, a row of knots is made. The ends of the knots are cut off to create a soft pile. An average knotter ties 6,000 to 8,000 knots per day. An average knotted rug contains around 2 million knots. You can probably work out how long it takes to knot a rug. Nevertheless, knotted rugs are a true addition to your interior.

Needle felting technique

The needle felting technique creates what is known as needle-felt. These durable 'pieces' of fabric consist of fibre fleeces and dry wool threads that are interlocked by countless needles with tiny barbs that are repeatedly pushed through the fabric. You can think of the material as 'indestructible'. This weaving technique is often found in spaces where many people walk. You might think of offices or public spaces, for example. Because it's so flat, the strength of the fabric is concentrated in the compressed fibres. As a result, water has no room between the fibres, making needle-felt moisture-resistant. The same applies to dirt—felt has no room for that either. The oldest pieces of needle-felt ever found date back to around 7,000 years before Christ. From the aforementioned properties and historical fact, we can safely conclude that this material will certainly last a while!