![]() Apart from these conventional uses, future-oriented implementations are also conceivable, such as the integration of switches in textile structures, the use of textiles for control purposes and protective covers for electronic components. Designs, team logos and company names can be applied easily and accurately for use in automotive interiors. The automotive sector, known for its high production efficiency, is likely to be particularly interested in Karl Mayer’s efficient 3D printing system because of the few working steps required, for example, to integrate reinforcements into door panels, roof liners and seats. ![]() Other opportunities are customized designs right through to 4D-printed shoes cloths - for instance through 3D-printed spacer textiles - and efficient production “on demand”. Shoes also benefit from the opportunity of being designed to be wear-resistant in areas which are under the most stress. For instance, partial reinforcements such as kinesio tapes or support areas for muscles and for stabilizing movement can easily be integrated in functional sport outfits. In the sport sector, where high demands are placed on product performance, the new 3D printing system is once again ahead of the field. Above all, the far greater flexibility in terms of design opens up completely new opportunities for successfully responding to increasing customer needs for individualization. Through direct printing onto the fabric, large quantities of textile articles can be decorated with logos, brand designations or team names. ![]() Thanks to these advantages, the innovation is particularly suitable for customizing products. The complexity of the machine handling is also reduced through a simple pattern system. The new 3D printing system from Karl Mayer combines the high productivity of warp knitting machines with the outstanding flexibility of additive manufacturing, thus offering the opportunity to cut production steps. Particularly advantages for the sports, shoes and automotive sectors The materials generally used in textile finishing are applied at a printing speed equivalent to a textile production of 85 square meters per hour with a warp knitting machine working width of 138 inches. ![]() The current printer version processes polyurethane and silicone without heat. A camera system and a pattern recognition software ensure highest precision during positioning of the printing head on the 2×1 meter printing field. It is mounted on an H-gantry and can be moved in all directions in space at a speed of 5 meters per second. The inline printing head can be moved quickly to every necessary manufacturing position. This involves the machine directly communicating with the printer’s pattern system to enable targeted control. With the new 3D printing solution, the textile is printed directly after it has been manufactured on the warp knitting machine. The new 3D inline printer really makes the most of its advantages, particularly when manufacturing prototypes and equipping of textile products with reinforced areas as well as design or function elements for additional benefits. In addition, the carbon footprint of newly developed products is good, since savings are made on material and energy-intensive working steps. Mass-produced articles complete with 3D-printed branding and functional elements are already firmly established in this domain,” noted Michael Kieren from Karl Mayer’s New Business Development team. The world of sportswear is already showing us what is possible. “3D printing allows us to completely rethink our whole approach to textile product design. The result is maximum flexibility and efficiency in manufacturing customized products. The innovation combines the warp knitting machine with the 3D printing system in a homogenous process according to the roll-to-roll principle. The KARL MAYER GROUP has recognized this and has developed a technological solution for combining warp knitted textile manufacturing with 3D printing. OBERTSHAUSEN, Germany - FebruThe combination of new technologies such as additive manufacturing with the traditional procedures used in the textile industry offers numerous potentials for product development and hence new market opportunities.
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