Artificial grass has revolutionized the way homeowners, businesses, and sports facilities approach landscaping. Whether it’s for a backyard, a playground, or a putting green, high-quality artificial turf provides a lush, low-maintenance alternative to natural grass. But what goes into making premium synthetic grass? At Smart Turf, we pride ourselves on manufacturing 100% USA-made artificial grass, ensuring superior quality and durability from start to finish. Here’s a deep dive into the detailed manufacturing process that brings Smart Turf to life.
Step 1: From Pellets to Yarn – The Foundation of Smart Turf
The journey of artificial grass begins with high-quality synthetic pellets. These small, plastic granules serve as the raw material that will ultimately
become the individual blades of turf. Smart Turf sources its pellets from a trusted USA supplier, ensuring that our artificial grass is 100% made in the USA.
The type of plastic used in artificial turf plays a crucial role in its performance and durability. Most synthetic turf manufacturers use polyethylene (PE) for the grass blades because of its soft texture, while polypropylene (PP) or nylon may be used for thatch layers or special applications. These raw pellets are formulated with UV stabilizers and colorants to enhance longevity and create the vibrant green shades that mimic natural grass.
This is also the step where we integrate Microban© additives into the yarn. We are proud to say that no other artificial grass manufacturer has this.
Step 2: Yarn Extrusion – Creating the Grass Blades
Once the pellets are ready, they move to the extrusion process, where they are melted and transformed into yarn. This is where artificial grass gets its texture, resilience, and natural appearance.
During extrusion, the melted plastic is pushed through specialized dies, creating thin strands of synthetic yarn. These strands are then stretched and cooled to enhance their strength and flexibility. The shape of the yarn varies depending on the intended use of the turf—flat yarn creates a soft, lush look, while textured yarn enhances resilience and recovery.
After cooling, the yarn is wound into large spools, ready for the next step in the manufacturing process.
Step 3: Tufting – Bringing the Turf to Life
Tufting is the process that gives artificial grass its recognizable form. This step involves inserting the yarn into a strong backing material, much like how a sewing machine stitches thread into fabric.
At Smart Turf, we use advanced tufting machines that punch thousands of needles through a primary backing, securing the yarn loops at a consistent height and density. The tufting gauge (or stitch spacing) determines the grass’s density—tighter spacing creates a more lush and natural-looking product, while wider spacing is ideal for sports applications where ball roll matters.
The height of the grass blades (pile height) varies depending on the product’s intended use.
For example:
- Playgrounds & Pet Turf: Shorter pile height for easy cleaning and durability.
- Landscaping: Medium pile height for a natural look and soft feel.
- Putting Greens: Ultra-short pile height for smooth ball roll.
See Smart Turf’s turfting process!
After tufting, the backing material still holds the yarn loosely, so the turf moves on to the next step: coating.
Step 4: Coating – Locking Everything in Place
The tufted turf is now coated with a durable backing material that locks the grass fibers in place. This is a crucial step in ensuring that the artificial grass remains intact for years to come.
Our backing process consists of applying a secondary coating, made from polyurethane to the underside of the turf. This coating provides:
- Strength & Stability: Keeps the yarn securely anchored.
- Longevity: Ensures the turf withstands heavy foot traffic, weather conditions, and UV exposure.
- Drainage Properties: Smart Turf products feature Smart Flow perforated backing for efficient water drainage.
Once coated, the turf passes through a curing oven where the backing is heated and dried, solidifying its structure.
Step 5: Rolling Up – Preparing for Installation
The final step in the manufacturing process is rolling up the artificial turf into large, manageable sections. Smart Turf rolls are 15’ wide and vary in length from 100’ to 120’. 
The turf is trimmed to its final dimensions and inspected for quality control, ensuring that every roll meets Smart Turf’s high standards.
Once the rolls are complete, they are packaged and stored, ready to be shipped to contractors, landscapers, and homeowners across the country. Because Smart Turf is manufactured in the USA, our customers benefit from:
- Shorter Lead Times: No long overseas shipping delays.
- Consistent Quality: Every roll is produced under strict quality control standards.
- USA-Made Trust: Supporting American jobs and industry.
Why Choose USA-Made Artificial Grass?
While there are many artificial grass manufacturers worldwide, USA-made turf offers distinct advantages over imported alternatives. Here’s why choosing Smart Turf’s American-made artificial grass makes a difference:
Higher Quality Control Standards – Every roll of turf is produced under rigorous testing and ASTM standards to ensure durability and safety.
Safer for Families & Pets – Our turf meets strict US safety regulations.
Eco-Friendly Manufacturing – We adhere environmentally responsible manufacturing processes, minimizing waste and emissions.
Faster Delivery – Unlike imported turf that takes weeks to arrive, Smart Turf offers quick turnaround times for U.S. customers.
We take pride in crafting high-quality, American-made artificial grass designed for durability, safety, and beauty. Our meticulous manufacturing process—from sourcing USA-made pellets to rolling up the final product—ensures that every square foot of Smart Turf meets the highest standards.
Whether you’re a homeowner looking to enhance your backyard, a contractor seeking premium turf for landscaping projects, or a facility manager in need of durable sports turf, give us a shout. By choosing our 100% USA-made artificial grass, you’re investing in superior quality, long-term reliability, and true American craftsmanship.