The process of carpet manufacture includes various methods that allow different kinds of fibers to be intertwined. The newest methods involve needle felting, which uses barbed or forked needles to create a carpet that is extremely durable. This method of carpet production is most common in commercial environments and high-traffic areas. The basic principles of design and the preparatory process are the same for both types of woven fabrics.
Until World War II, wool was the only fiber used in carpet manufacturing. Consequently, the government started allocating most carpet manufacturing plants to war necessities, which led to a significant drop in the market. This prompted manufacturers to look for a replacement fiber and introduce a wool-rayon blend in 1940. Today, wool-rayon blends are widely used for carpeting. It has several benefits over wool, but remains relatively expensive.
Early in history, nomads woven thick carpets to protect tent floors. Using simple looms, these textiles were easy to transport. Early looms were made of two forked branches and a wooden bar that held the suspended warp. The weft threads were then flattened using a wooden bar. The loose ends of the warp formed the pile of the carpet. One of the oldest known examples is the Pazyryk carpet, which was discovered in Central Asia around 500 B.C.
During the 1950s, cotton was a substandard fiber used in floor coverings. In response, manufacturers experimented with rayon, staple nylon, and chopped and spun nylon. But these materials did not have the bulk needed for a high-quality tufted carpet. Eventually, DuPont Corporation invented bulked continuous filament nylon. Later, Monsanto introduced similar products, which made cotton a viable alternative for floor coverings.