Industrial Felt-making A MODERN production Blending Designated proportions of wool and other raw or recycled stock are run through a mixer until the fibres are thoroughly opened, uniformly blended and free of foreign matter. Carding The picked and blended material is delivered by automatic feed through mechanical combing machine to create gossamer-like carded webs. Web Crossing Carded webs are crossed at right angles to provide transverse as well as longitudinal strength, then rolled into batts. Hardening Layers of carded batts are stacked to create the desired thickness and then conveyed into hardener. Agitation between vibrating platen and stationary bedplate, in combination with controlled conditions of moisture, heat and pressure, cause the fibres to soften, entangle and interlock. Fulling The re-rolled hardened batt is put into a fulling machine where hammers pound and turn the felt to shrink the fibres. This process is regulated to control density, thickness and texture. Drying and Tentering The felt is fed through convection hot air dryers and mechanically stretched-tentered-to return the shrunken material to its original width. Return to Top of Page

Traditional Felt-making An ANCIENT process... Making felt by hand for use as shelters, clothing and groundcovers is an ancient craft common to parts of Asia and the Middle East. 1) Wool is sheared and carded by hand 2) Loose batts of carded wool are laid on a base that is made of either an old felt (called the mother felt) or of woven rushes. 3) Hardening and fulling are performed by rolling the wool and the rushes into a bundle, soaking it with hot water and soap, and vigorously working it, often with the feet. Sometimes the material is rolled around an axle made of wood, and dragged behind a camel or horse. 4) The felt is laid in the sun to dry