Artificial grass is made from different synthetic materials: polyethene, polypropylene, and nylon. These materials are used to imitate the blades of real grass. Some types of artificial grass are manufactured with silica sand and rubber granules to enhance the bouncy texture of the turf. The artificial turf is the fibre or the “blades” that make up the artificial grass.
The main materials used for making artificial grass are those mentioned above. However, there could be variations in the materials depending on the function and usage. For example, the materials used for making artificial grass for a lawn is different from that of a soccer field. Specific requirements are needed for a specific use.
Since artificial grass is made from synthetic materials, the end product should still be good for the environment and safe for human and animal use. Before artificial grass is made, the materials are checked to assure that the best quality of the final product is achieved.
The process of making artificial grass is somewhat the same as the process of making carpets. Here is the step-by-step process of how it is made.
- Special chemicals will be added to the basic materials to make the grass. Polyethene, polypropylene, nylon, or a combination of the three will be used as the main materials. Chemicals will protect the finished product from UV rays to prolong its appearance. It will also give the artificial grass its green colour. Different shades of green are applied to make the “grass” look more realistic. The materials will be mixed until the desired consistency and texture are achieved.
- The mixture will then enter an extruder machine. This equipment will produce long and thin strands.
- The strands will be spun and gathered into a loose rope. It will then be pulled and flattened multiple times. Lastly, it will be woven into a yarn.
- The produced yarn is heated. Once it is heated enough, it will be set into the desired twisted shape.
- The material will then go to the tufting machine. It will be pulled and looped hundreds of times through the nylon backing to create the artificial tufts. This process will create hundreds of rows of tufts put together. You now have created the artificial turf, which is the main component of the artificial grass. It serves as the surface of the “grass.”
- The artificial turf will pass through a dispenser where latex coating will be spread on the back. Latex is also coated on a separate backing. These two pieces are placed and sealed together using a roller.
- Heat lamps will be used to cure the latex coating. Latex curing is needed to provide a strong bond to the turf and backing.
- Once the latex is cured, any stray tufts will be cut off the artificial grass to create a smoother finish. After this process, the artificial grass will come out with a soft and fluffy finish resembling real grass.
- Lastly, the end product will be rolled, packaged, and shipped.