How It’s Made

Understanding the Flooring Materials in Your Home

At Floors By Tomorrow, we believe homeowners should feel confident not just in their installation, but also in the materials underfoot. This page walks you through how flooring is made — from raw materials to the finished surfaces installed in homes throughout Denver, Aurora, and the surrounding Colorado area.


Whether you’re considering carpet, hardwood, vinyl plank, or laminate, understanding how each type is manufactured helps you make better decisions about style, durability, and maintenance.

How Hardwood Flooring Is Made

Solid hardwood flooring starts with sustainably harvested timber — most commonly oak, maple, hickory, or walnut. Trees are milled into rough planks and then kiln-dried to reduce moisture content and prevent warping.

The Process:

  1. Sawing & Grading: Logs are cut into planks using plain, quarter, or rift sawing. Each board is graded based on grain and appearance.
  2. Drying: Wood is air-dried or kiln-dried until it reaches optimal moisture content.
  3. Milling: Planks are shaped with tongue-and-groove edges to allow for tight-fitting installations.
  4. Sanding & Finishing: Some are sold unfinished; others are factory-coated with stain and multiple protective layers.
  5. Quality Check: Final boards are inspected for color consistency, flatness, and structural soundness.


Engineered hardwood is constructed with a real hardwood veneer over multiple plywood layers, enhancing stability and reducing movement from humidity.

How Carpet Is Made

Carpet starts with synthetic or natural fibers — most commonly nylon, polyester, polypropylene, or wool. These fibers are turned into yarns, which are then tufted into backing materials.

The Process:



  1. Fiber Extrusion: Synthetic pellets are melted and formed into fine filaments or spun into yarn.
  2. Tufting: Yarn is stitched through a primary backing using thousands of sewing needles.
  3. Dyeing: Some carpets are solution-dyed during fiber extrusion; others are dyed after tufting.
  4. Secondary Backing: A secondary layer (usually polypropylene) is added and fused with latex for dimensional stability.
  5. Finishing: Carpet is sheared, treated for stain resistance, and rolled for shipping.


Different construction styles — such as loop, cut pile, or patterned — impact feel, durability, and appearance. Carpet padding is produced separately, typically from recycled foam or rubber compounds.

How Luxury Vinyl Plank (LVP) Is Made

Luxury vinyl plank is a high-performance, multi-layered synthetic flooring product designed to replicate natural wood or stone. It’s known for being waterproof, scratch-resistant, and highly durable.

LVP Construction Layers:


  1. Backing Layer: Provides structural support and dimensional stability.
  2. Core Layer: Often made from stone-plastic composite (SPC) or wood-plastic composite (WPC), adding rigidity and waterproofing.
  3. Printed Design Layer: A high-definition printed image simulates wood grain or stone pattern.
  4. Wear Layer: A transparent, abrasion-resistant coating protects against scratches, scuffs, and wear.
  5. Top Coat: An additional UV or stain-resistant finish may be applied.


All layers are fused using heat and pressure to form durable planks. Many LVP options feature click-lock edges for floating floor installation.

How Laminate Flooring Is Made

Laminate flooring is engineered using compressed wood-based materials topped with photographic imagery and a protective wear layer.

Laminate Layers:



  1. Bottom Stabilizing Layer: Balances the board to prevent warping.
  2. High-Density Fiberboard (HDF) Core: Compressed wood fibers bonded with resins.
  3. Image Layer: A printed, high-resolution image of wood or stone.
  4. Wear Layer: A clear, durable layer made from aluminum oxide for surface protection.


The layers are assembled using direct pressure laminate (DPL) or high-pressure laminate (HPL) techniques. Boards are cut into planks with interlocking edges for easy floating installation.


Laminate provides a cost-effective, scratch-resistant alternative to hardwood, especially in active households or rental properties.

What Flooring Manufacturing Means for You

Understanding how flooring is made can help you:

Choose the Right Product

Know which materials fit your lifestyle, climate, and budget.

Understand Product Lifespan

Engineered materials offer better stability in Colorado’s dry climate.

Plan for Maintenance

Know what finishes or wear layers your floors have and how to care for them.

Ask Smarter Questions

Be informed when comparing products or working with contractors.

Avoid Gimmicks

Recognize real quality over marketing terms like “waterproof” or “luxury.”

We educate our clients during every consultation to help them select products that perform as well as they look.

Ask Questions, Get Honest Answers

At Floors By Tomorrow, we don’t push the most expensive product — we help you choose the right product. Whether you want sustainable wood, stain-resistant carpet, or waterproof vinyl, our team provides education, not just estimates.