Hand-knotting: This is the most traditional and time-consuming method. Skilled artisans create knots by hand, tying individual yarns around the warp threads that form the foundation of the rug. The rug knots can be tied tightly or loosely, depending on the desired texture. This process requires expertise and can take months or even years to complete for larger, more intricate and higher quality / finer weave area rugs.
Hand-tufting: In this method, a design is first drawn on a canvas or cloth stretched over a frame. Then, using a tufting gun, yarn or wool is punched through the backing material to create loops. The loops are often sheared to achieve a uniform rug pile height. Hand-tufting area rugs is a faster technique compared to hand-knotting and allows for intricate designs.
Flat-weaving: Flat weave rugs, also known as kilim rugs, this method involves interlacing the rug warps and rug wefts to create a flat texture rug. Flat weave area rugs do not have a pile and are typically lightweight as they are thinner than regular hand knotted pile rugs.
Other types of area rugs that have flat woven approach to their construction are:
Soumak Rug Weaving
Aubusson rugs (similar to the way wall hanging Tapestries are woven)
Dhurrie Rugs
Machine weaving: Machine-made area rugs are created using mechanical power looms. These rug weaving looms automate the weaving process, allowing for faster and very precise rug productions. The rug patterns and designs area programmed into the loom, and the machine weaves the rug by mechanically interlacing the yarns. While machine-made rugs lack the individual craftsmanship of handmade area rugs, they are often cheaper and more affordable rugs and can be produced in larger quantities more quickly.