Artificial grass is based on a mixture of plastic granules and additives like UV stabilizer and colouring agents. This mixture is heated and pressed through an extruder head under pressure. This process results in the creation of individual synthetic fibers. The shape of the fibers is determined by the extruder head. Roughly speaking, there are two types of fibers: fibrillated and monofilament. The mix of synthetic materials used differs per product and supplier and ultimately determines the quality of the end product.
After the grass fibers have been made, the blades are reinforced. They are made resistant to strong tractive force and temperature fluctuations . The grass fibers are then coiled around large spools (bobbins) and shipped to the various artificial turf manufacturers. The bobbins are then placed on a machine that is four or five meters in width, which uses needles to push the blades of grass through a backing.
The principle is similar to a sewing machine and the process is called tufting. The type of fiber, fiber height, distance between the needles, etc. determines the appearance of the turf and suitable usages. To secure the grass fibers in the backing, a liquid mixture is added, which is then hardened in an oven. This fixates the fibers. At this point, the grass roll has earned the name artificial turf and is ready for sale and installation.