Custom Rug Fabrication

A Modern Twist to an Old World Tradition



Custom rug fabrication is part old world technique and part modern technology. Take note of our past projects and you’ll discover how we transform the ancient tradition of rug making into an exciting new art form.

In essence, it’s a two pronged approach whereas carpet colors are inlaid into a main field piece (background color) and then carved and sculptured. This carving technique can have a stunning three dimensional effect.

Over the years, techniques for custom rug fabrication have been fine tuned. Now the current custom rugs being produced today can easily match the highest quality tufted wool rugs.

The flexibility of this product is appealing as well. This is because custom shapes and sizes are easily accommodated. Typical rectangular rugs are ok, yet it’s now possible to create free flowing organic shapes that have an impressive custom look and feel.

Design ideas are readily available all over the internet. Some sites, like our residential based site, specialize in custom rug fabrication and feature design ideas to spark your interests. Designs can be inspired from your own interior themes, fabrics, and artwork.

The Raw Materials used in Custom Rug Fabrication

Currently, in the US there are only a handful of mills that produce the majority of carpet seen in carpet stores across the nation. Nylon is the fiber of choice for a few reasons, mainly cost and availability. Most carpet found in office buildings and residential homes is produced from nylon fibers.

This nylon yarn is actually spun from a thermoplastic base which is easily heated into liquid and molded or in this case spun into a thread. Nylon was developed as a synthetic substitute for yarns made of silk and wool. Silk is harvested from cocoons made by silkworms, and as you may have guessed, not exactly cost effective.

Because silk and wool are more expensive to produce, the shift toward nylon has been more out of necessity than anything else. Over the years the carpet mills have done an extraordinary job of replicating the texture, feel, and durability of silk and wool. Most of us would be hard pressed to tell the difference.

Wool carpet is available in some US mills, however the cost is much higher. Wool can easily be substituted for nylon if specified. In other words, you can  produce wool rugs with same techniques found in custom rug fabrication.

The Tools and Equipment

The equipment required to fabricate custom rugs is remarkably light weight and inexpensive. Most of the tools are specialized hand tools, including a high powered shearing device that, given the right training, allows for the rugmaker to bevel intricate designs within the plush carpet. In my training programs, I include my trusted vendor list. I share my key suppliers for tools and materials. Check my FAQ’s page for more on this subject. Read more of my informative articles found here on the Advice and Tips page.

Pricing Points

As with any product or service, you will find time (labor) and materials to be the main costs. Custom rug fabrication can be labor intensive and does cost more than typical machine made rugs found online and at your local carpet dealer. I have answered this question regarding average costs on rugs in the FAQ’S section of this site.

As we have seen here, it is now possible to create unique personalized area rugs out of nylon fibers or wool fibers. Custom rugs can be produced in any shape and size. Design ideas can be inspired from numerous sources online and within your own home.

All the Best,

Russell Webb
Sundari Design LLC