How Is Artificial Grass Made？

Artificial turf, as the star of ground paving materials in sports venues, garden landscaping, commercial and residential spaces, has won the favor of the masses with its excellent durability, low maintenance costs and charming aesthetics. However, have you ever been curious about how this artificial grass, which is so realistic that it can almost look like the real thing, was made? Today, let us uncover the mystery of its production process.

Step 1: Raw Material Preparation

First, we need to carefully prepare the raw materials. These include key elements such as grass yarn raw materials, base fabric and backing glue. Grass fibers, as the core element for manufacturing artificial turf, are mostly made of two polymer materials: polypropylene (PP) and polyethylene (PE). The base fabric is often made of polypropylene,net or composite with non-woven to provide stable support for the grass fibers. The backing glue is the key that firmly adheres the grass fibers to the base fabric. We commonly use styrene-butadiene latex and PU adhesive. We will make precise selections according to the different needs and characteristics of the lawn or the needs of the customer.

Step 2: Yarn Extrusion

Next, we enter the extrusion process. This is a critical process that converts raw materials into grass fiber. After the raw materials are mixed, heated and melted by the extruder, they are finely extruded into filaments through a specific mold, and then precisely stretched by a wire drawing machine to form synthetic grass fibers with excellent strength and toughness. During this process, we can also produce grass fibers of different colors and shapes.

Precise control of the extrusion process plays a vital role in ensuring the quality and performance of artificial grass.

Step 3: Twisting

After the grass yarn is produced, we will twist it according to the needs. Generally, straight yarn needs to be twisted, but curved yarn does not.

The prepared grass yarn is twisted through a twisting machine. The working principle of the it is to twist and weave several grass filaments through a specific device to form a twist-like grass rope. This process is actually a change in the look of the grass yarn, making it tighter and stronger. Also it provides a good foundation for subsequent tufting and backing processes. The artificial turf produced in this way not only looks close to natural lawn, but also better durability and stability during use.

Step 4: Tufting

Then, we enter the tufting stage. Lay the base fabric on the workbench of the tufting machine, install and adjust the tufting needles according to the required grass fiber density and length. The number and spacing of tufting needles can be customized according to customer needs to ensure the quality and appearance of the final product. Start the tufting machine, and the tufting needles will pierce the grass yarn into the base fabric to form neat loop pile or cut pile. This process requires precise control of the depth and speed of the tufting needles to ensure that the grass filaments are firmly anchored to the base fabric while maintaining the smoothness and uniformity of the lawn.

Step 5: Backing

Then, to enhance the durability of the lawn, we apply a backing material to the back of the lawn. These backing materials, such as PU or styrene-butadiene latex, can not only firmly fix the grass filaments, but also effectively prevent the lawn from deforming or falling off.

We apply the adhesive evenly on the base fabric. During this process, the thickness and uniformity of the glue must be strictly controlled to ensure good adhesion between the glue and the fiber bundles.

After the coating is completed, the glue needs to be cured. Typically, this step is accomplished by drying. The time and temperature of the drying process should be adjusted according to the specific adhesive material and product requirements.

After the curing process is completed, perform a quality inspection on the glued artificial turf. Check whether the backing is even, without bubbles or omissions, and whether the bonding between the base fabric and the grass silk is firm. If there are any substandard products, they need to be repaired or re-glued.

Step 6: Cutting

After the lawn production is completed, we will perform precise cutting and meticulous finishing according to the customer's specific needs to ensure that the lawn reaches the predetermined size and shape. In addition, we will conduct strict quality inspections on our lawns to ensure that every piece of lawn meets high quality standards.

Step 7: Packing

Finally, the artificial turf will be carefully rolled up and packaged properly, ready to be shipped to the customer. We use advanced packaging technology to ensure that the lawn does not suffer any damage during transportation, so that customers receive a flawless product.

Through these series of carefully designed production processes, artificial turf can not only perfectly simulate the appearance and feel of natural grass, but also show excellent advantages in terms of durability and maintenance costs. With the continuous advancement and innovation of technology, the quality and performance of artificial turf will become closer and closer to that of natural lawn, bringing people a more beautiful, comfortable and lasting green environment.