Page 52 - February-March-2020

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Fresh looks created by the

fourth dimension

The newly configured RDPJ 6/2 EL is opening up new patterning

possibilities and market opportunities with 4D-KNIT products

KARL MAYER has added a new dimension to the mechanism – and the distance between them is
third dimension of warp-knitted spacer textiles in the constant and uniform. Differences in height can only
shape of new types of fabrics with a wide range of be produced between one fabric and another. On the
surface designs. These innovative articles are known other hand, different fabric heights can be produced
as 4D-KNIT. Their relief-like designs on both sides are over the entire surface when producing 4D-KNIT
rather unconventional, extravagant and diverse for textiles, and the differences in height can be used to have produced a cover for office chairs with the side adjustable knockover comb bar distance, this
warp-knitted fabrics, and are enabling KARL create the patterns. Pronounced relief-like designs wings, seat panel and seat back made almost machine is a good, all-round machine. With a
MAYER’s customers to expand their business areas. are produced, which are stabilised by using bulky entirely in a single piece. The fabric perfectly matches distance of 1.5 to 2.5 mm, 4D-KNIT items and
KARL MAYER is meeting demand by developing yarn to create a cushioning effect. the geometry of the seat, and is extremely double-layered fabrics can be produced and, at a
4D-KNIT. “We ran with an idea from the market and hardwearing. It can withstand 20,000 abrasion cycles distance of between 2.0 and 8.0 mm, conventional
optimised it,” says Takayama Hirokazu, the Senior Three-dimensional patterns, openwork designs, in a stress test without being damaged. Depending spacer textiles can be produced - and jacquard
Director of NIPPON MAYER, the centre of excellence semi-made-up goods and much more besides on the pattern and type of yarn used, the fabric patterns can also be worked. This wide range of
for double-bar raschel technology within the The special look of 4D-KNIT textiles is based on 3D weight can be adapted to suit the intended end-use. patterns minimises the investment risks.
company group. A higher production rate is the main motifs, whose shape, height and location can all be KARL MAYER has pro- duced patterns with fabric
improvement. Compared to other technologies used varied. The relief-like, permanently stable elements weights ranging from roughly 370 g/m² to just under Optimism before the sales launch
to produce fabrics with a similar appearance, warp can be combined to produce creative designs. 500 g/m². The lower limits are created by the This innovative, double-bar raschel machine should
knitting can deliver a higher production rate. Trials Extensive processing trials carried out at NIPPON threedimensional effects. “The three-dimensional go into production in the fourth quarter of 2019. Kay
with producing shoe fabrics clearly show the MAYER show just what can be achieved here. The look is lost if we use too little yarn or if the filler yarn is Hilbert, the Head of Product Portfolio Management at
differences here. Whereas textiles for 200 pairs of pattern developers and specialist technologists in too fine,” explains Oksana Wizechowski. This product KARL MAYER, is optimistically looking forward to the
shoes can be produced per hour using double- bar Japan closely studied the possibilities offered by the developer was involved in the extensive processing sales launch. The newly configured RDPJ 6/2 EL and
raschel technology, flat weft knitting machines can newly configured RDPJ 6/2 EL, and have developed trials over a period of several months at NIPPON selected 4D-KNIT items were on show at the last
only produce enough for 1.5 pairs of shoes over the more than 50 patterns over the last two years. The MAYER. The importance of finishing became clear as ITMA in Barcelona, and were a highlight of KARL
same time period. The new configuration of the RDPJ designs include strict, geometric arrangements with the work progressed. The bulky yarns only reveal MAYER’s stand. “News of our new development
6/2 EL double-bar raschel machine is the reason high/low effects, as well as sweeping, their voluminosity to create the shape of the relief quickly spread around the fair. Even yarn producers
behind its high productivity and the unique three-dimensional wavy designs, bright fruit patterns structures when the textile is relaxed and heat is had heard about the 4D-KNIT and came to learn
appearance of the fabric. The modified version and complex, imaginative designs having different applied. more about it on our stand,” says Kay Hilbert. He and
enables textile constructions to be produced that are height profiles. Openwork patterns can also be his team discussed many interesting projects with
completely different to the conventional constructions integrated seamlessly into the textiles. These are in Well-thought-out machine technology the visitors. Some of the visitors seemed very keen to
typical of 3D warp-knitted textiles. especially high demand as breathable zones in This new version of the RDPJ 6/2 EL is available in a invest, and they discussed ideas for new
functional clothing and shoes. Contrasting, gauge of E 24 and a working width of 138". Its applications. So far, the end-uses for the lightweight
High/low effects make all the difference two-colour effects can also be produced by the types exceptional patterning possibilities are based on an fabrics have targeted the outerwear and activewear
Conventional warp-knitted spacer textiles are made of yarn used. In addition to these interesting patterns, intelligent technical configuration and the sectors and, for the heavier fabrics, they have been
from two cover faces with a pile layer made from important elements, such as cut edges, can be wellthought- out design of the knitting elements, aimed at the automotive, home textiles, shoe and
monofilament yarns between them. The two sides of integrated for further processing, and combined with KARL MAYER’s tried-and-tested piezo mattress sectors. However, it quickly became evident
the fabric can be patterned – if the double-bar near-netshaped products can be produced. For jacquard technology. The machine also features the from the conversations being held at the fair that the
raschel machine used is equipped with a jacquard example, the product developers at KARL MAYER manufacturer’s new LED lighting concept. With its market potential goes much further.

February/March 2020 January/February 2020

KARL MAYER’s LONG CHAIN BEAMER