How carpet is made – synthetic
Synthetic carpets are made from a variety of synthetic fibers, such as nylon, polypropylene, and polyester. The process of making synthetic carpet typically involves the following steps:
Production of synthetic fibers: Synthetic fibers are made from various chemical compounds, which are melted and extruded through small holes, called spinnerets, to form long strands of fiber. The fibers are then cooled, stretched, and cut into the desired length.
Blending and carding: The synthetic fibers are blended together and then passed through a machine called a card, which combs the fibers into a uniform web.
Spinning: The fiber web is then fed into a spinning machine, which twists the fibers together to form a yarn. The yarn is then wound onto a spool or bobbin.
Weaving or tufting: The yarn is then used to create the carpet either by weaving or tufting. In the weaving process, the yarn is passed back and forth through a series of warp (vertical) and weft (horizontal) threads on a loom to create a fabric. In the tufting process, the yarn is sewn through a backing material using a tufting machine to create loops of yarn that stand up from the backing material.
Finishing: After the carpet is made, it is typically treated with a variety of chemicals to give it certain properties, such as carpet cleaning protector for stain resistance, colorfastness, and durability. The carpet may also be treated with a secondary backing material or a coating to give it additional strength and stability.