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The
technique of tufting was actually already around in the 18th and early
19th century. Then there was a revival of the technique around 1895. Table
cloths and Bed spreads were adorned by tufts of cotton or candle wick.
This was done using a sowing needle, tufts of yarn were pulled through
the cloth and then cut, so the longer threads stuck out in the front,
then the cloth was washed hot so it shrunk and kept the tufts in place.
Around 1926 the first tufting machines were invented, they looked a bit
like sewing machine then still with just one needle.
A couple years later they started adding needles. Tufting was mostly used
to adorn bedspreads.
In the thirties there was another technique that started to become popular,
so-called needle punch; a piece of cloth was tightened on a frame and
with a special needle yarn would be punched in to form a tufted adornment.
During the Second World War all materials were used to make army materials,
only the lesser quality yarns were left over.
The quality of these yarns were not good enough to be used in bedspreads,
this has been probably the moment where the first rugs and carpets started
to be made. In these years the broad-tufting machines were developed so
wider carpets could be tufted.
The technique then was mostly used for carpet and bath rugs.
The quality back then was most definitely not of the standard it has now,
for example mostly a cotton primary backing was used and the tufts were
not tightened that well so over the years you would walk the yarn out.
In the forties they started to use burlap as a backing material, this
kept the rugs in better shape and the tufts could be put in closer together,
so a denser carpet could be made.
Then in the fifties they started to use rubber latex to secure the tufts
into the backing.
Only in the eighties a polypropylene backing was started to be used, because
burlap was not moisture resistant.
Hand tufting then was developed as a repair technique, to fill in missing
bits when one of the machine needles had failed.
These mending guns were further developed for small projects.
For
a hand tufted rug or wall hanging I tighten a polyester backing material
on a vertical frame and draw the design on this backing. I work on the
back of the rug, so the actual rug forms on the other side.
The machine blows the yarn under high pressure through the backing and
a little rotating knife cuts the piles, the yarn is in a U-shape in the
backing. How long it takes to make a rug depends on the design, for example
on how often color needs to be changed and of course the size of the rug
also plays a part.
Rugs can be made in any shape and color, but I can also work in different
pile heights, from 0.6 to 1.8 inches. The standard pile height is 0.8
inch, for 10 square feet I use about 10 lbs of wool.
When the whole rug or wall hanging is finished a layer of latex is brought
on to fasten the yarn. Then a burlap backing is brought on and a second
layer of latex. A special backing to protect your floor could also be
brought on, this is on request.
When you want to use the rug as a wall hanging a hanging system is attached,
using Velcro. The rug is neatly cut to even it out and is then ready to
be shipped.
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