#Research & Development

2021-02-04

Leading technology for high-level research

Textile reinforcements in concrete do not require any corrosion-related covering and thus make building cheaper, more environmentally friendly and more versatile. Completely new architectural solutions can be implemented through the slender construction forms of textile concrete. The Institute for Textile Technology (ITA) at the RWTH Aachen University is investigating what is actually possible. Already between 1999 and 2011, the Construction Composites Research Group developed textile reinforcement structures for concrete structures as part of the Collaborative Research Centre 532.

KARL MAYER’s new BIAXTRONIC® CO at the RWTH Aachen University for innovative semi-finished fibre products

The work was carried out on a KARL MAYER Malimo machine, and then continued at the ITA after 2011. Recent textile projects placed high demands on machine technology and required new investments. Once again, the ITA opted for a model from KARL MAYER. “The Malimo was already a great machine. Unfortunately, it was just getting on a bit,” says Martin Scheurer from the Department of Textile Machinery and ITA, when explaining their choice. He and his colleagues also valued KARL MAYER as a competent partner when it came to questions and service. They are now excited about the newcomer: a BIAXTRONIC® CO was delivered to Aachen at the end of 2020. It had been completely assembled and functionally tested in advance at KARL MAYER Technische Textilien in Chemnitz, since it is a tailor-made model. The high-performance warp knitting machine with course-oriented weft-insertion was equipped with novel functions that will open up new research paths for the ITA and its research partners.

Martin Scheurer, employee at the Department of Textile Machinery and Institute of Textile Technology at the RWTH Aachen University is looking for the research work on the BIAXTRONIC® CO © 2021 KARL MAYER

A made-to-measure model

BIAXTRONIC® CO is predestined for the production of biaxial non-crimp fabrics and composite structures, and was equipped with specific features for its use at the ITA. One of these is KAMCOS® 2. The latest generation of KARL MAYER’s Command System offers an ethernet interface for integrating the machine into an existing network. This enables participation in future-oriented research topics such as Industry 4.0, inline quality control, sociology and process chain networking.

“We are planning to transmit the data from the producing machine via ethernet to the Internet of Production Excellence Cluster at RWTH Aachen University. The cluster deals with production research in high-wage countries,” explains Martin Scheurer. The BIAXTRONIC® CO for the research facility was also equipped with an EL pattern drive. Electronic guide bar control and the ability to vary process parameters inline contribute to the production of locally adapted, tailor-made textiles.

What’s more, the product quality can also be significantly improved. For example, Martin Scheurer wants to use the EL drive to investigate the influence of the warp knitting thread in different lapping variants on the geometry of the roving used and thus on the behaviour of the finished grid structure. Other details that favoured the BIAXTRONIC® CO are a working width that meets standard industrial practices and the possibility of feeding basic substrates such as nonwovens in a standard process.

Research- and practice-based projects

With BIAXTRONIC® CO, ITA researchers want to further develop and produce reinforcement structures for concrete matrices in particular. Functional models and prototypes for other areas of application are also to be produced on the machine. Martin Scheurer and his team want to produce reinforcements for wound dressings and hybrid warp knitted fabrics on a nonwoven substrate, for example. The combination of grid structures with other materials facilitates fundamental research into geotextile applications. Projects for filtration technology can also be implemented. The production of unidirectional (UD) non-crimp fabrics for fibre composites and of flat warp knitted fabrics for heating textiles, which can be used in the mobility sector, are also conceivable. In addition to research and development work, the ITA has its sights set on production practice using the BIAXTRONIC® CO. Users of weft-insertion machines can use the capacities and expertise in Aachen to optimise their production processes, produce prototypes of new textile structures or even test the processing of new materials.

Save the date: discovery awaits

Interested parties can find out what can be done with the BIAXTRONIC® CO on 19 April 2021. To kick off the new year, the ITA invites you to discover the new machine as part of a one-day industrial event. “We look forward to exchanging information with industry and research partners from all over the world,” says Martin Scheurer. He is looking forward to stimulating discussions on the needs and future developments relating to companies in the manufacturing sector in particular.

RDJ 6/2 in E 32: Finesse in Motion

The appearance of sports and casual shoes is as diverse as their applications, ranging from sporty to stylish and from functional to fashionably practical. In particular, spacer fabrics produced on highly flexible KARL MAYER double needle bar raschel machines with Jacquard technology are in high demand for manufacturing these trendy shoes. These efficient production machines enable attractive designs with integrated multifunctional zones on one or both fabric surfaces, such as breathable mesh structures. Flexible in size and positioning, these features enhance both aesthetics and wearing comfort.

3D designs with a wow factor made on HKS 4-M EL ECO: When crepe, ruffles, and sheer fabrics redefine fashion

Seersucker, flip-flap items, Fırfır, or crepe materials: structured fabrics have long been more than just a passing trend. They lend timeless looks depth, dynamism, and an exciting tactile dimension. Whether classic striped patterns or modern solid-color interpretations, these versatile pieces pair perfectly with casual and business-casual outfits and effortlessly create a modern look.

More patterns, less effort: the MULTI-MATIC® at Rohleder

Rohleder is one of Europe’s most modern weaving mills. For over 80 years, the family-owned company has been developing and manufacturing premium fabrics for brands, retailers and private customers – 100% Made in Germany. This success is made possible by a consistent focus on design, quality, and functionality, as well as by continuous investment in state-of-the-art production facilities. Rohleder also relies on innovative technologies in warp preparation and has been collaborating with KARL MAYER for many years. As recently as 2023, a MULTI-MATIC® was delivered to the company’s headquarters in Konradsreuth.

Novel flame-retardant and recyclable fiber-reinforced composite

Airplanes and passenger trains must meet strict safety requirements, including fire safety standards. This calls for materials that are flame-retardant, lightweight, robust, and scalable. Empa researchers, in collaboration with their industry partner Elantas, have now succeeded for the first time in making such a material – a composite – fully recyclable.

From smart jackets to laser technology: Mona Neubaur explores Textile Factory 7.0

As part of her summer tour, North Rhine-Westphalia’s Minister for Economic Affairs and Climate Action, Mona Neubaur, visited Textilfabrik 7.0 in Mönchengladbach to experience the project’s innovations first-hand. Under the motto “smart and clean”, the visit focused on innovative technologies and sustainable alternatives for textile production - from smart jackets to the decolourisation of textiles using fungal cultures.

Outdoor Industry Association completes Clean Heat CoLab initiative

The Outdoor Industry Association (OIA) has completed its multi-year Clean Heat CoLab initiative, bringing together outdoor brands and technology experts to accelerate the adoption of electrified process heating in textile manufacturing. The collaboration focused on reducing emissions from thermal processes such as dyeing, washing and finishing, which remain among the most carbon-intensive stages of textile production.

Cotton Brazil Dialogues 2026 concludes with 50 international participants immersed in Brazilian cotton production

The Cotton Brazil Dialogues concludes its 2026 edition after a series of technical visits to farms, cotton gins and reference centers, as well as workshops focused on Brazilian cotton production. A total of 50 participants from 14 countries took part in the field trips. The initiative is led by the Brazilian Association of Cotton Growers (Abrapa) and the National Association of Cotton Exporters (Anea), with support from the Brazilian Trade and Investment Promotion Agency (ApexBrasil).

WHILL selects Teijin’s tough, lightweight Carbon Fiber Composite for new last-mile mobility

Teijin Limited announced today that WHILL Inc., a global leader in inclusive mobility technology, has selected Sereebo® P CFP series, a carbon fiber-reinforced thermoplastic (CFRTP) material, for key structural components of the upcoming WHILL Model C Lite. Sereebo® P CFP series provides high strength, light weight, design flexibility and system cost advantages to the Model C Lite, which is a battery powered, single-seat, last-mile device. This new model combines maneuverability with light weight and one-handed folding to ensure ease of handling and operation.

ZymoChem secures $4 million in renewed federal funding to advance U.S. biomanufacturing of critical materials and their supply chains

ZymoChem, the specialty chemicals company dedicated to bringing decarbonization, sustainability, and supply chain resiliency to the chemical industry through innovative biological manufacturing, today announced the resumption and expansion of its federal research portfolio. The company has been notified that previously paused work under a $5 million U.S. Department of Energy (DOE) program is officially back on, to be joined by continuing collaborations with three of the nation's premier national laboratories.