Creating a luxury handwoven merino lambswool blanket

Introduction: Creating a handwoven merino lambswool blanket

Creating a handwoven blanket to co-ordinate with a newly decorated client's lounge was an opportunity to work with the client at each step of the process from the design to the weaving of the blanket. In this blog post, I explore the steps involved, the client input and the stages in the creation of the handwoven blanket.

Understanding the client’s vision

It helps when starting a commission to have a clear understanding of the client’s vision. For this project, I was fortunate to find that the client had already created a mood board for her lounge decoration. The mood board demonstrated a cohesive design incorporating navy, blue and soft beige tones and we spent time together studying the interplay of the colours and textures. The client had made beautiful choices with respect to the colours and textures of both her fabrics, papers and paints. As a professional upholsterer she had plans to upholster two sofas in a blue fabric as well as making blinds in a mottled blue and beige colourwary. Complimentary wallpaper patterns and paint colours had also been chosen. In addition, a rug for the new lounge had already been purchased which included the same colours with a tiny accent of soft pink. This visual collection served as a terrific guide helping us to work together to select a range of yarns for the weaving project.

Fabric swatches in blue and beige tones on a wooden surface, featuring patterns and textures. — The mood board

Selecting colours for the warp

Choosing colours for the blanket's warp and weft was the next step. The warp threads form the backbone of the fabric, while the the horizontal weft threads adds character and depth. The colours shown below were chosen at this stage for the warp, a white, electric blue, navy and soft pink. The plan was to include each of these colours in equal amounts.

Four spools of yarn in pink, navy, white, and blue sit on a wooden table. The background is plain with a neutral wall color.

Selecting the weft colours

The client chose a range of 4 brown / beige shades which were to be used as weft threads in addition to the 4 other colours already chosen for the warp.

Four spools of yarn in brown, gray, and beige with colorful tops sit on a wooden table with fabric samples in the background.

The importance of small scale sampling

Before embarking on the floor loom weaving I decided it would be wise to create a sample weave. Using my TabbyandTweed square frame loom I wove a twill sample using the chosen yarn colours. I also created some yarn windings which is another way of looking at yarn colours before weaving. Small scale sampling is a vital part of all of my weaving projects. This process enables me to very quickly weave a small woven square using the chosen yarns. Sampling is simple, quick and also economic The process gives me a visual idea of how the colours will weave together. It would not be good for me to spend two days measuring the warp and dressing the loom (along with the expense of the merino lambswool yarn) only to find out that the chosen warp wasn't right.

Yarn cones in blue, gray, and navy with a weaving frame showing a plaid pattern. A comb and yarn

This sample weave was shown to the client and whilst the client had initially been drawn to the bolder navy shades, after looking at the small sample swatch, she felt that the lighter colours resonated more with her style. The sample sparked a discussion that helped refine her preferences. Ultimately, we opted for a combination of soft beige, muted blues with the soft pink, with less navy. This adjustment demonstrates the importance of feedback in the design process, ensuring that the design of the final product takes into account the views of the client.

Larger scale sampling

With the colour choices refined, the loom was dressed with the selected warp threads and I proceeded to weave a large sample, this time a meter length piece of fabric. Initially I had shown the client a range of woven designs and a simple straight 8 pattern was chosen. The large sample was woven with this design. This sample was washed and finished and this larger sample allowed the client to physically feel the quality of the merino lambswool and visualize the final accessory in her lounge. At this stage she identified that one of the paler beige yarns didn't seem to fit well in the final fabric. I was in complete agreement so going forward we decided to remove this yarn from the weft.

Close-up of a multicolored herringbone wool fabric in blue, beige, and brown, creating an intricate patchwork pattern.

Weaving and finishing the final fabric

With the colour scheme finalized, I began the exciting phase of weaving the entire blanket. A total of 5 meters of carefully constructed fabric was woven. Attention to detail was crucial during this phase. The uniformity of the weave and the combination of the chosen yarn colours all played a key role in achieving the blanket's overall quality and final appearance. It was decided to weave the fabric to give a symmetrical design so the number of weft rows in each yarn needed to be carefully counted to maintain this pattern.

A loom with a checkered pattern in pink, blue, and white, featuring a wooden shuttle. Bright, natural light illuminates the scene.

Once woven, the fabric was washed and fulled. This finishing step is vitally important. The fine merino lambswool is very fragile and is coated in spinning oils to give it a little more strength. However, breakages do occur so once the fabric has been removed from the loom loose or knotted warp threads need to be individually repaired. Then came the washing step which serves to remove the oils. Washing by hand is vital to ensure that the oils are removed fully without over felting the fabric. A perfectly fulled fabric was created which was soft and bouncy with a beautiful drape.

A close-up of a soft fabric with a checkered pattern in pink, blue, white, and brown, neatly twisted at the center.

Making the final blanket

The fabric was then sewed to create a wide blanket. The patterns were matched seamlessly down the centre. This size was intentionally chosen to offer a cozy covering for the lounge, ensuring warmth while perfectly complementing the lounge colours.

Hands sewing a blue, pink, and white plaid fabric with pins. The pattern features herringbone and checks, creating a cozy and focused mood.

Celebrating Custom Craftsmanship

Weaving this handwoven merino lambswool blanket has allowed me to use and develop my own textile design and weaving skills. This project has also been exciting because I have been able to work in collaboration with the client taking her ideas, mood board and thoughts into account. This case study highlights the importance of client involvement at every stage, from the first discussions of mood boards to the final product reveal. This approach emphasizes that a luxury handmade accessory is not merely a result of the materials used but the design process, traditional skills and the many steps in the creative journey.

A blue, gray, pink plaid blanket draped over a dark blue chair with wooden legs. Cozy and inviting setting.

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Emma Baker Handwoven Textiles

Case Study: Commission to create a luxury handwoven merino lambswool blanket