How Bespoke Logo Mats Are Made | Full Process

Bespoke entrance matting is more than a tool for trapping dirt and moisture. While it is an effective way to keep interior flooring clean and extend its lifespan, it also serves as a tactile form of branding that reinforces brand identity from the moment someone steps inside.

From initial design through to final finishing, Heckmondwike creates custom mats tailored to each company’s unique requirements. Built for durability as well as design, they combine performance and aesthetics to deliver a lasting impression.

Digital Design Development

The process begins with a digital logo or design, the visual foundation of the brand.

Once approved, the artwork is processed through Gerber CAD, enabling precise translation from digital design to production-ready format. This ensures even the most intricate brand details are accurately reproduced at scale.

From here, the design moves into production, where materials and manufacturing techniques bring the final product to life.

Material Preparation Stage

Heckmondwike’s signature fibre-bonded product, Diamond, is used in the production of the mat through a specialised needle-punching technique, which mechanically interlocks fibres to create a dense, durable, and hard-wearing surface designed for high-traffic commercial environments.

This carefully engineered material not only brings the design to life, but also ensures long-lasting performance under constant footfall, resisting fading and fraying over time.

Precision Laser Cutting Process

The digitally rendered logo is then transferred into a precision laser cutting system.

This stage is critical in ensuring exceptional design accuracy, including sharp edge definition, precise lettering, and faithful reproduction of brand colours. Each element is carefully made to maintain visual clarity and consistency across the finished product.

Unlike printed alternatives, which rely on surface-level application, laser-cut designs are formed directly from the same high-performance matting fibres. This integral construction means the design is built into the product itself, ensuring it will not peel, crack, or fade over time, even under sustained heavy footfall.

Pre-Bonding Assembly Stage

The individual cut-out pieces are assembled upside down, much like a jigsaw puzzle, and carefully fitted into their corresponding sections within the base mat.

To secure the design, a layer of white scrim is first applied to the reverse of the logo, followed by a layer of hot-melt adhesive. A second layer of scrim is then placed over the adhesive, encapsulating the design elements. Heat is subsequently applied to activate the bonding process, permanently securing the structure to the base mat.

This layered construction ensures the logo remains firmly fixed in place, delivering a durable, seamless finish designed to withstand heavy commercial footfall.

Loose-Lay Backing Integration

Where a loose-lay format is required, a rubber waffle backing is incorporated to enhance stability, grip, and long-term in-use performance.

Final Trimming and Edge Sealing

The final stage consists of precision trimming of any excess material and edge sealing to prevent fraying, ensuring long-term durability and a refined, high-quality aesthetic finish.

Want to see a behind-the-scenes look at our process? Watch how Heckmondwike creates bespoke logo mats and carpets from design through to production.

Meet Gerber – How Heckmondwike Makes Bespoke Logo Mats & Carpets

Ready to start your custom entrance mat project? Email us at sales@heckmondwike-fb.co.uk with your enquiry, and our team will be happy to help.