Variable density tufting patterns

In a tufting machine of a type having a row of reciprocating needles inserting a plurality of different yarns through a backing fabric moving longitudinally through the machine, where the backing fabric and needles are laterally shiftable relative to each other, a method for varying the stitch density in the manufacture of tufted patterns from pixel mapped designs comprising the steps of:

• creating a pixel-mapped design for tufting comprising a plurality of pattern colors;
• establishing a sewing gauge and a corresponding sewing gauge density for the tufting machine to employ with the design;
• threading the tufting machine with at least a first yarn and a second different yarn in desired positions;
• designating the different yarns to at least one pattern color;
• assigning yarn feed increments to the pattern colors;
• specifying a density less than the sewing gauge density for at least one pattern color;
• setting a shift pattern for at least one of the row of needles or the backing fabric;
• processing the pattern data in view of the machine sewing gauge, shift pattern, yarn feed increments, and yarn positions to create pixel mapped pattern design information;
• translating the pixel mapped pattern design information into tufting machine instructions;
• and
• operating the tufting machine to create tufted fabric having at least a first yarn with a lateral stitch density lower than the density of the sewing gauge of the tufting machine and a second yarn.