The Twice Woven Rug series reimagines the traditional flat-woven rug through an innovative production technique rooted in time-honoured weaving traditions. A collaboration between MOS Architects and Urban Fabric Rugs, this collection begins with modular strips of flat woven rugs and recombines these strips into larger, intricately layered compositions—creating rugs that are, quite literally, woven twice.

When we embarked on this project with MOS Architects, the objective was to develop a rug – or a collection of rugs – which reflected their particular voice in design and architecture. It was an opportunity for the designers to act freely. It was an invitation to be playful, yet thoughtful – to explore the new medium and respond with their own unique perspective.

Initially, we worked with MOS Architects’ principals, Michael Meredith and Hilary Sample, to explore a variety of manufacturing techniques including hand-knotted, tufted and woven rugs. Each manufacturing technique informed an almost completely different design proposal from MOS Architects. We experimented with pile heights, colours, colour blending and the textures capable with these various crafted techniques. As we explored each technique, we also investigated the primary fibres of the proposed rugs – from wool and other natural fibres to recycled PET.

These explorations, refinements, sample making and adjustments took a tremendous amount of time and research. Our design research and development went on for over 4 years. Ultimately, MOS Architects circled back to the simple flat weave – an age-old production technique of producing a flat rug surface without knots, but by interlacing warp and weft threads to create a dense, durable textile.

The textural, handmade quality of these flat woven rugs is what captured the designers’ attention. One can see the artisan’s hand in the microscopic structure of these rugs – a regular, repetitive, geometric structure with natural imperfections and irregularities resulting from the materials and natural processes that produced them. Moreover, the flat weave is timeless, utilitarian and unpretentious – qualities MOS Architects found especially appealing for their Twice Woven Rug collection.

Once we narrowed in on the flat woven rug technique, the designers began exploring irregular shapes, overlaps, layering and other design possibilities with this format. As with anything they do, the designer duo explored notions of material, colour and scale using physical models;

“We cut strips of paper and wove them together; a simple childish activity. We made models and drawings. We made different arrangements. We looked at them. We made some small ones that we carried around with us in our notebooks. We made some larger ones that we pinned on the wall. We made some large ones to sit on. We tried different colours. We tried patterns. It took time”

Following these paper model experiments, we began producing smaller, modular strips of rug that would then be recombined into larger, more complex assemblies that make up an area rug. Like the paper strips in MOS’ experiments, these flat woven modular strips played the role of the warp and weft threads of a conventional rug.

The possible method of recombining and holding these strips together was a major design decision to address. Simply weaving them together would not be sufficient owing to their scale. They needed to be fused or fixed in some way. Various stitching details were explored to hold these re-woven strips in place. Initially, we re-wove the woven modules together tightly and perpendicularly, then stitched them into place by hand to keep them together. After our first samples were produced this way, the designers began pushing the boundaries of this assembly method, adding more playful irregularities and spaces between the modules.

Finally, we devised what is now referred to as the ‘Twice Woven Rug’, wherein 25cm wide strips of flat woven rug are loosely woven together like enormous warp and weft threads, referencing the method of production which created the modules to begin with. Hence, the Twice Woven Rug is an innovative product borne of a production method established through the vigorous study of a traditional craft.

The Twice Woven Rug collection is made of 100% New Zealand wool, a renewable resource that grows year after year. Wool is also a biodegradable fibre that leaves no harmful waste behind. Wool naturally purifies indoor air by absorbing harmful VOCs. It is hypoallergenic, dust-resistant, and moisture-wicking. In short, it is one of nature’s super-materials. We are a Good weave Certified company, meaning our rugs are produced by adult artisans earning a living salary in certified work environments. It also means our products help to fund positive changes in communities by increasing access to education programs.

Category:Floor and Wall CoveringAward Year:2025Designers:Michael Meredith and Hilary Sample, MOS Architects, New York, USA and Andrei Zerebecky, Urban Fabric Rugs, Saskatoon, Saskatoon, CanadaManufacturer:Urban Fabric Rugs, Saskatoon, Canada