Key Materials & Manufacturing Process
Core Components
Fibers: The most critical element, typically made from polyethylene (PE), polypropylene (PP), or nylon (polyamide). PE offers softness and natural appearance, PP is cost-effective for low-traffic areas, and nylon excels in durability for high-use spaces like stadiums.
Backing: Two-layered (primary and secondary) to secure fibers. Primary backings are usually polypropylene or polyester woven fabrics, while secondary backings (often latex or polyurethane) add stability and prevent fiber loss.
Infill: Materials like crumb rubber (recycled tires), silica sand, or organic infills (coconut husk, cork) that support fibers, improve drainage, and reduce surface temperature.
Manufacturing Steps
Fiber Extrusion: Plastic resins are melted and extruded into yarns, which may be textured or twisted to mimic grass blades.
Tufting: Yarns are stitched into the primary backing using tufting machines, with pile heights ranging from 10mm (residential) to 60mm (sports fields).
Coating: The backing is coated with latex or polyurethane to lock fibers in place.
Infill Application (for sports/heavy-use turf): Infill materials are spread evenly across the surface to support fiber uprightness.
