Artificial turf : where does it come from and how is it made ?

Artificial turf : where does it come from and how is it made ?

- Categories : Actualities - Reading time : min

Initially intended for large-scale landscaping or sports facilities, the manufacture of artificial grass has evolved considerably over the yearss. But how did it come about ? How is it manufactured ? Let's take a closer look at its history and our manufacturing process.

Summary : 

1. When was artificial grass created ?
2. How is Exelgreen artificial grass made ?
3. The sewing of synthetic turf strands, also known as tufting.
4. The backing
5. Finishing synthetic grass
6. Why choose artificial grass ?

When was artificial grass created ?

In the 1960s, Astroturf developed synthetic grass for sports fields. Realism was not a priority for manufacturers at the time, but covering a sports field with artificial grass meant significant savings in water and maintenance costs. Artificial grass is much easier to maintain than natural grass, and its appearance is no longer dependent on the weather. Made from nylon, synthetic sports turf is enjoying a certain success thanks to its durability and natural green appearance.

Initially used in the United States for multi-sports pitches, it has since become the benchmark surface, economical and resistant to all sports. Since the 1970s, the manufacture of artificial grass has been constantly improved for the comfort of sportsmen and women, with the addition of sand or rubber granules to improve the cushioning and resilience of the strands. Secondly, artificial grass became increasingly popular in the home for garden and terrace landscaping.

It wasn't until the 2000s that artificial grass arrived in Europe. In France, Exelgreen was one of the first European manufacturers to produce and sell top-quality ornamental artificial turf for the home, making it accessible to all.

- 1960 :  Introduction of synthetic materials
- 1976 : Expansion of sports turf at the Montreal Olympic Games
- 1980 : Design of artificial turf fields specifically for outdoor and team sports (short pile and plastic materials)
- 1990 : Development of the first synthetic turfs with sand infill
- 2000s : Realistic manufacture and creation of artificial turf for home use, artificial turf is no longer reserved solely for sports facilities, but also for ornamental use.

Artificial grass on stairs

How is Exelgreen artificial turf made ?

First and foremost, it's important to prepare your soil with care. Artificial grass should be laid on level, on a clean soilideally weeded to prevent weeds from growing back.

Our tip : on loose soil, in addition to weedkiller, we recommend the use of geotextile. Don't forget to check the slope of your soil to avoid water stagnation. Find all our advice on soil preparation here.

Today's artificial grass is very different from that of the 60s and 70s, both in terms of the materials used and the manufacturing techniques employed. The raw materials (polyethylene, polypropylene or polyamide) come in the form of microbeads which, once heated, melted and stretched, are transformed into a continuous, resistant thread. Polyethylene is used for high yarns, while polypropylene is used for curly artificial grass yarns. The curly yarns are designed to add thickness to the artificial grass and give it an even more natural look, depending on the color.

Artificial grass rolls
Artificial grass rolls

The sewing of synthetic turf strands, also known as tufting


Once the threads have been produced, the second step is to wind them onto large spools. The threads are then sewn onto the backing of the artificial grass using a large industrial machine known as a tufting machine. This process is identical to carpet manufacture. Once sewn, the threads are cut to the desired height.

Exelgreen's latest innovation is based on 3D thread assembly technology. The asymmetrical assembly of the three types of thread produces a highly realistic result, very close to nature. Exceptional quality for exceptional artificial grass.

The backing

The backing of Exelgreen synthetic grass is usually made up of two layers : the first is a UV-stabilized woven fabric. This layer serves as a support for the turf coating. The second layer provides an additional guarantee against the fibers pulling out or separating over time.

Once the strands have been sewn to their bases, it's time to coat them for a solid bond. This step is crucial to the durability of synthetic turf. Finally, we use a polyurethane- or latex-based coating, depending on the model, to attach the synthetic strands to the backing.


Artificial grass finishing

Packaging artificial grass

Throughout the manufacturing process, Exelgreen artificial turf undergoes laboratory tests for strengthresiliencesoftnesscomfort and tear resistance. The final stage in the manufacture of the synthetic turf consists of making small holes in the base every 10 cm to ensure drainage of rainwater.

The rolls are then ready to be checked, packed and shipped. Our synthetic lawns are available in pre-cut and made-to-measure formats, adaptable to all sizes of soft or hard surfaces.

Why choose to lay artificial grass ?

- No maintenance or gardening constraints
- A beautiful green lawn, maintained all year round
- Can be laid on any surface
- Several heights, colors and densities of strands possible
- Guaranteed UV-resistant for 6, 8 or 10 years
- No yellowing in contact with the sun
- Reduced risk of allergies
- Choice of cut-to-size or custom rolls
- High-quality turf made in Europe
- Investment in an economical, long-lasting surface
- Easy to install without the need for a professional, and much more besides.

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