In the gripper Axminster method of manufacturing the yarn is presented to the gripper, which is a mechanical grabber that selects the correct coloured yarn at the point in the design where that colour is needed. The pile of the carpet (the yarn) is inserted into the backing as it is woven and cut to length, creating J-shaped tufts to create a cut pile, velvet surface. The process locks in the fibre to create a carpet of high durability and performance retention as well as a strong, three-dimensional structure that is extremely suitable for high-traffic or large installations such as hotel corridors or public areas.
Modern day electronic jacquard allows for intricate designs and colours to be used. Up to 16 colours are available within each design, although with some newer technologies up to 30 colours are possible within the design. Design definition is excellent as the pattern is an integral part of the woven carpet which also gives greater dimensional stability making pattern matching much easier. The only limit to design is the extents of the room.
Spool Axminster manufacturing is almost obsolete, due to the pattern limitations and advancement in current weaving technology. Each row of the carpet design has been pre-wound onto individual spools which are then presented to the loom grippers in much the same way as with a Gripper Axminster. There is virtually no colour limitation with Spool Axminster, but there is a limitation to the size of the pattern repeat.
Over-tufting is an Axminster woven carpet with hand-tufted elements incorporated in the design and construction. Over-tufting can be produced in any pattern, including complex designs. Normally, this level of customisation is only possible using hand-tufted carpets, which is a costly and time-consuming process. However, because the carpets use a combination of Axminster weaving and hand tuft techniques, they have a fast turnaround and they’re less expensive to produce. Typically there are five distinctive over-tuft effects: level cut with carving, level cut pile with level loop pile, level cut pile with lower loop pile, level cut pile with higher cut pile and Level cut pile with different yarns.
Over-tufting information courtesy of Modieus Flooring