Usually the process of creating a custom rug starts with our sales team. Our representatives located throughout the US are happy to come visit with your design team with our latest samples demonstrating our design techniques and elements that will make your rug a unique work of art – including 100% NZ Wool, Bamboo Silk, Viscose, Nylon, Swarovski Crystal Elements and more.

After our sales consultation, the design process really begins. Our design staff will discuss suggested construction techniques appropriate for the rug’s application and to enhance your design while maintaining your project’s budget. Once color poms are picked and finalized, the next step to designing your custom rug is the development of a CAD design. Zenith Rugs is able to turn around CAD designs within 48 hours.

To produce your full sized custom tufted rug, the CAD design is transferred via a full size stencil to the rug’s backing material which is stretched on a frame scaffolding.  The wool and other yarns are each applied one color at a time, and up to six yarns of different colors may be combined at a time to create different color patterns.  The tufting is done by hand, as either cut pile, loop, or a combination of both, and different weaving patterns may be employed for textural interest.  When the tufting is complete the rug is removed from the frame and the backing materials and fire retardation treatments are applied.  The rug will then have final elements done, such as outline carving, shearing, and trimming. Each rug is then carefully inspected and packaged before delivery.