What are the methods of carpet construction?

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The majority of the carpet supplied in the U.K. is tufted rather than woven. Woven carpets can be...

The majority of the carpets are tufted rather than woven. Woven carpets can be handmade or machine-made and tend to be high end or more expensive. All carpet used to be hand woven. Huge advantage in the carpet industry was the invention of tufting equipment in the 1930s. Tufting equipment is versatile and efficient and allows for a whole range of styling and design effects in an extremely cost effective manner. A tufting machine looks a lot like a sewing machine with hundreds of needles across the width that tuft the yarn into a substrate. The tufting machine punches the yarn into this grid of fabric that's called the primary backing.

The tufted carpet are then dyed to the desired colour. A secondary backing (the woven material seen on the back of most carpets) is then attached to the dyed carpet by using a latex coating between the dyed carpet and the secondary backing. This carpet is passed through an oven to cure the latex. This  adds dimensional stability and also locks in the tufts. The carpet has a fuzzy surface at this point so the carpet must go through a finishing operation which is composed of shearing off the fuzz and trimming the carpet to the proper finished width. You now have carpet which can be shipped to the retailer.