Part old world technique and part modern technology blends to transform the ancient tradition of rug making into an exciting new art form. So what exactly is custom rug fabrication?

It's a process that features several main steps and admittedly some of these steps are closely guarded trade secrets. In essence, it's a two pronged approach whereas carpet colors are inlaid into a field piece 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 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

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 silks. 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 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.

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, when properly used, bevels intricate designs within the plush carpet.

Pricing Points

The bulk of costs generally reflect the labor involved – higher complexity equals higher costs. Custom rug fabrication does cost more than typical machine made rugs found online and at your local carpet dealer. You have to weigh out the benefits and decide if it's the right direction that appeals to you.

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.