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Machine Made:
Machine made rugs are woven on power looms operated either by hand, machine, or computer. The design and colors are determined, and a computer card is created which tells the computer which size and color it needs to produce. The loom is strung with a warp of jute, or cotton.

The rug is then woven using wool, nylon, polypropylene, olefin, or other suitable yarn. Wool is the most durable and easiest to clean, as well as the most expensive. Some of the common synthetic materials are olefin, which is resilient and if heat set, is not as shiny as many others; polypropylene, which tends to flatten more readily; and nylon which is generally less durable. All of the synthetics do not clean as well as wool, but can be more cost effective.

There are two types of looms used to create three different categories of oriental reproductions: Wilton and Axminster. Each of these can be designed to achieve different pile heights and density, as well as various finishes and qualities.


Hand Woven/Knotted:
Most weavers tie an average of 5000 to 6000 knots per day. Generally speaking, the finer the weave (smaller the knot), the more detailed the design may be. Handmade rugs are often judged in part by the knots per square inch. A coarse weave is typically less than 40 knots, medium is between 40-90, fine is between 90-180, and very fine is 180 and up.

Most importantly, the weave should fit the design. The finished rug needs to have good clarity in the design, so it doesn't look fuzzy or blocky. A fine weave becomes more important if you want a very detailed pattern, and less important if you desire a simplistic design. Contrary to popular belief, the average rug weaver is a 25 year old male who comes from a family that has probably been weaving rugs for many generations.

Once the rug has been woven to its finished size it is cut off the loom and goes through a series of steps in order to be completed. The ends are usually finished by weaving the weft threads through the warp to create the selvage. This is a tight flat-weaving process often used to protect the knots; as well as to add a decorative or finished look.

The remains of the warp strands actually become the fringe. Then the sides of the rug are overcasted in the same material the rug is woven in. Next the carpet is hand sheared, washed, and is then ready for inspection. This completes a typical hand knotted rug weaving process.
(want a little more detail on hand knotted rugs? Click here

Flatweaves:
This category includes Dhurries, Kelims, and Soumaks; among other types. They are all pileless, reversible rugs, which are created when a weft is woven across a warp in a basketweave fashion, making a design. The weft is usually wool and the warp is either cotton or wool. These flatwoven carpets, like their handmade counterparts, are created with natural or chrome dyes. The quality is again determined by the amount of labor involved, i.e. the intricacy of the weave; and the quality of the materials.

Braided:
The first braided rugs were created by Early American settlers using old pieces of blankets, clothing, canvas, and other materials. There are several different types of braids. Flat braids are braided around two guide yarns, which makes them more durable. Tubular braids contain a single core, around which the surface yarns are knitted. Tape braids use three solid pieces of material braided in a traditional fashion. Yarn braids consist of several three-ply yarns which make up one part of the three elements of a braid. Braided rugs are woven with many different materials ranging from nylon, to cotton chenille, to wool, and even blends of different materials. The quality is again determined by the tightness of the braid and the materials used.