KARL MAYER is inviting the sector to an exchange of ideas at Techtextil, stand 3.0/E 18, 14.-17.5.2019 in Frankfurt and to explore the latest RACOP-NW at the In-house Show in Obertshausen.
At the Techtextil 2019 in Frankfurt am Main, KARL MAYER will be demonstrating warp-knitted textiles in Hall 3.0/E 18, with an exceptional level of performance. KARL MAYER is also a trendsetter in the area of digitisation. The manufacturer has grouped all its digital solutions under the KM.ON brand and also presents them at its Techtextil booth.
In addition, KARL MAYER invites to an In-house Show accompanying the fair at its headquarter in Obertshausen. The event is easily accessible by bus transfer and will be premiering a nonwovens machine RACOP-NW.
|14 – 17 May 2019
Hall 3.0/E 18
|14 – 17 May 2019
KARL MAYER Obertshausen
KARL MAYER impressed its visitors with an innovative show at ITMA ASIA + CITME and presented the future of warp knitting – digital, sustainable and technically innovative.
The combination of new technologies, such as 3D printing, and the traditional textile sector opens up many opportunities for product development. To explore these possibilities is the aim of the workshop called „Additive manufacturing for the textile industry“. The event took place for the first time in January 2018, it was extremely successful and will now be repeated.
The next workshop will take place on 13th May 2019, which is the day before the start of Techtextil in Frankfurt/Main. In its role as host, the cooperation partner KARL MAYER will again make its premises available to the event. The organizer, the Textile Research Institute Thüringen-Vogtland e. V. (TITV), expects roughly 100 guests. Nine speakers from research and practice will highlight the topic of „Additive manufacturing“ in particular. In this respect, the company ViscoTec Pumpen- und Dosiertechnik GmbH will give a lecture on viscous media of the future, Heraeus Noblelight will present IR emitters, and DFKI will provide a contribution on the subject of „Additive manufacturing of modules and housings for electronic components on textile“. Besides, Pedex GmbH will deliver a speech on materials for filaments for FFF-3D printing.
During the programme accompanying the event, KARL MAYER will present the new premises of its Academy. The company’s own qualification site will only move to the new rooms in April 2019. Moreover, the visitors will have the chance to gain first insights into the manufacturer’s TEXTILE MAKERSPACE. An exhibition with offers from industry and research on additive manufacturing will round off this workshop.
More information about the event under https://www.karlmayer.com/de/additive-fertigung-in-der-textilindustrie/.
You can still send your application to Mrs. Siegl under: firstname.lastname@example.org.
KARL MAYER is showcasing warp-knitted textiles having an exceptional level of performance in hall 3.0/E 18 at Techtextil 2019 in Frankfurt. On show will be products with integrated electrical conductivity and shaping characteristics from the new TEXTILE MAKERSPACE platform, an extremely efficient textile solution for protecting buildings, and a completely new generation of warp-knitted spacer textiles. KARL MAYER is also inviting people to attend an in-house show, to be held at the same time as the fair, at its headquarters in nearby Obertshausen. This event is easily accessible by bus transfer and will be premiering a new nonwovens machine for the visitors. KARL MAYER is also a trendsetter in the field of digitisation. This manufacturer has grouped all its digital solutions under the KM.ON brand, and will also be showcasing this system on its stand at the Techtextil.
RAPID TEXTILE– the quick way to new solutions
Textiles with an excellent performance and lower manufacturing costs can be produced by combining the possibilities of additive production with warp knitting technology. Examples of this include warp knits functionalised by 3D printing and these are being presented at Techtextil.
KARL MAYER has grouped together all its activities relating to the use of new technologies and innovative products under the concept of RAPID TEXTILE. They form part of the TEXTILE MAKERSPACE system, a platform that offers the space to try things out, develop new products and think outside the box.
TEXTILE CIRCUIT – the quick way to electrifying designs
Electrically conductive textiles are a hot topic at the moment and can be produced in a variety of different ways. The easiest method is to directly incorporate conductive yarns during fabric production on the machine.
TEXTILE CIRCUIT, another element of TEXTILE MAKERSPACE, shows the potential of warp knitting here. Conductive zones offering maximum flexibility in terms of geometry, dimensions and location can be produced on KARL MAYER’s multibar raschel machines. Examples include inductive charging stations and the remote control of robots, and these are being demonstrated at Techtextil.
New solutions for patterns with plastic effects
Double-bar raschel machines have become firmly established in the production of warp-knitted spacer textiles featuring a variety of designs. A new model is now enabling completely new designs to be produced, i.e. warp-knitted textiles with decorative, relief surfaces. Instead of the spacer layer, three-dimensional design elements are worked on the upper and lower sides. The designs can be shaped and positioned almost without any restrictions, and can be combined with openwork designs. This is opening up a new dimension in near-net-shaped production in particular.
Security panels made from weft-inserted warp-knitted textiles – efficient cut protection for buildings and vehicles
Burglars frequently use chainsaws and drills during attempted break-ins, but they can be stopped effectively by a new type of patented security panel with weft-inserted warp-knitted textiles in the core. On contact with the cut-resistant textiles, the rotating tools quickly release large amounts of fibres from the material. These become entangled and the tool is stopped. The highly effective security panels are also very light and can be applied very easily to e.g. security doors, armoured vehicles, vaults and cash machines.
New raschel machine for web bonding – more opportunities on the nonwovens market
A model in the new RACOP-NW series will be demonstrated at an in-house show in Obertshausen at the same time as Techtextil. This efficient nonwovens machine produces stitch-bonded nonwovens from feed webs, a technology that offers many advantages. This process produces nonwovens having textile characteristics, such as elasticity and voluminosity, which is not the case when using chemical bonding agents. Furthermore, much less energy is consumed compared to thermal processes. In addition to these general advantages, the new RACOP-NW model also offers an exceptional cost:benefit ratio. It is also extremely flexible and can, therefore, be used in a variety of applications. A RACOP-NW, 160″, gauge E 14, is producing a textile for the application area heating textiles at the in-house show.
The supersoft, stretch, high-end velour fabric on this page is setting the trend in the apparel sector. This cuddlesome textile caresses the skin and body. With its gentle drape, it contours the female form with seductive lines, and its attractive shimmer adds a touch of glamour.
It can be used to produce eyecatching evening wear, which emphasising the body, as well as comfortable lounge wear for relaxing on the sofa. The ultra-comfortable pieces range from silky pyjamas, through tracksuits, to bathrobes and under garments, and have also been acceptable attire for the street since 2017. This casual look is in high demand from both men and women alike, especially during the cold months of the year.
Behind this warp-knitted textile, with its high powers of seduction and exceptional wear comfort, is a machine that delivers maximum performance. The fabric was produced on an HKS 3-M, 280″, in E 32 on KARL MAYER’s stand at ITMA ASIA + CITME 2018 in Shanghai. To produce the fabric, ground guide bars, GB 2 and GB 3, worked a counter-notation tricot lapping from polyester, FDY and elastane. GB 1 was also processing polyester. In combination with a textured microfibre yarn as a DTY version, an extra-fluffy surface was produced after raising.
The underlaps made from the microfibre yarns are raised to produce the velour layer – a process that requires experience and know-how. With stretch fabrics in particular, there is a danger that the fabric will tear if the process is not carried out correctly. As long as all the processing stages are managed correctly, a durable, easy-care fabric can be produced. The technology of warp knitting means that the fibres in the pile of the textile have a high pullout resistance, since the pile-forming layer is firmly tied into the ground by stitches.
For many years, KARL MAYER has been developing innovative shoe fabrics on its warp knitting machines. A wide variety of textiles, which are setting the trend on the market, can be produced on its high-speed tricot and double-bar raschel machines. The latest developments are aimed at reducing the number of processing steps in the production chain.
Uppers manufactured from a single piece are nothing new. In the sports shoe sector in particular, textile designs, which reproduce the butterfly contours of the entire upper shoe area, are creating quite a stir. KARL MAYER has gone one step further with integrated production. This company uses its double-bar raschel technology to also incorporate the insole directly into the textile product. The covering for the lower area of the shoe is produced during the warp knitting process on an RDJ 5/1 and is joined at the sides with the butterfly shape. A short seam is all that is needed to close the shape of the shoe to which the actual sole is applied directly by injection moulding. This modification to the production process enables making-up costs to be reduced by as much as a third.
But the potential of the double-bar raschel technology is also manifold in terms of design: Different names can be worked to personalise the shoes, as well a different serial numbers and a wide variety of patterns.
No matter if exclusive shirtings and suitings with multicoloured patterns and in small production runs or high-quality furnishing textiles and upholstery articles with striking designs in large fabric widths – KARL MAYER’s MULTI-MATIC® is always much in demand if it comes to flexibility, quality and efficiency. Compared to present conventional counterparts, this allround machine enables to increase the production of sample warps fourfold and that of plain warps even eightfold. The system provides an automatic colour change: 128 yarn guide fingers are individually controlled and precisely guided without any loss of speed. The positioning accuracy of the yarn selection is 0.05 mm, with an acceleration of 200 m/s². The results are premium-quality products. The beams having lengths of up to 1,500 m are characterized by uniform lap build-up, constant yarn tensions and precise material laying.
Flexibility and rapid amortization – the recipe for success for „made in Europe“
With this performance it goes without saying that the MULTI-MATIC® pays off even after a short period of time. „In case of an optimum economic use, the payback time is less than four years“, this is the experience of Dieter Gager, Vice President Sales and Marketing of KARL MAYER’s Business Unit Warp Preparation.
So far, the most feedback has been coming from the Italian market. The land of fashion has a lot of manufacturers who rely on collections with diverse patterns, high level of quality and short order cycles. The companies need premium warps for patterning and production. Nevertheless, during the last five years Dieter Gager and his sales team have been registering a growing interest in this machine type also from another country: namely from the fabric manufacturers in Portugal. „In the recent past we sold six MULTI-MATIC® machines to Portugal. A seventh machine is currently under negotiation“, explains Dieter Gager. Main reasons for the favourable investment climate in Portugal are the extremely fast style changes of the leading brand suppliers. Fashion companies like H&M and ZARA provide new collections twice a month, so that the supply chain is put under significant time pressure. The proximity to the sales and logistics centers becomes an important success factor, so that Europe is again an important production location – and Paulo de Oliveira can also benefit from this development, for example.
Paulo de Oliveira relies on the MULTI-MATIC®
This family-run traditional company was founded in 1936 by José Paulo de Oliveira as a weaving mill and has its registered office in Covilhã. In the course of its history, the enterprise has developed to a fully integrated textile company with an export share of more than 90 %. Today, the vertical production capacities include a spinning plant, a weaving mill and a finishing department including a dyeing section. On an area of 40,000 m² the Paulo de Oliveira company produces 10 million square meters of fabric per year (worsted fabrics), being one of the 3 biggest wool producers in Europe. As far as the machinery and equipment technology is concerned, this company fully relies on state-of-the-art models for all its production areas. Paulo de Oliveira has always understood that the company’s equipment with the latest available technology is the prerequisite to produce high-quality articles at a competitive price, and within reasonable delivery times.
The highest investments during the last few years are focused on warp preparation as well as weaving. Main objective of the spending was to make the production process even more flexible: It should be ensured to manufacture more demanding articles in ever shorter series and with ever shorter lead times and with very high quality.
So, the first MULTI-MATIC® machine was ordered in 2013 and in 2018 there followed another model which was installed by mid of October. The Portuguese company uses KARL MAYER’s warp sampling machine to produce premium beams for high-quality worsted suits. In the words of Mr. Dr. Luís Oliveira, today’s Managing Director and one of the sons of the company Founder: “The machine is fast, flexible and helps us to save energy and yarn.“
KARL MAYER is demonstrating that it is even closer to its markets and is increasingly participating in trade fairs that focus on applications and end-uses. Consequently, this textile machinery manufacturer was exhibiting for the first time at the ISPO sports trade fair, held from 3 to 6 February 2019 in Munich. With its modern, welcoming design and wide range of products to attract visitors, KARL MAYER’s stand quickly became a real magnet for the public. The team of experts from the company’s Textile Product Development Department welcomed roughly 400 visitors from home and abroad. Many of them were specialists with specific issues to discuss, and just under 150 high-quality conversations were recorded.
Most of the visitors were curious to examine the attractive presentation of selected warp-knitted textiles on show. A range of innovative, warp-knitted spacer textiles with three-dimensional patterns, air-permeable jacquard designs, and a shoe style with the design fully integrated into the surface were being showcased. RASCHELTRONIC® textiles, which deliver compression and breathability in the same piece, stretch, sporty lace items and functional, warp knitted meshes were also on show. “Our counter display proved to be a real attraction. Many of the visitors stopped, touched the fabrics, and wanted to know more about their production and performance,” says Gabriela Schellner, the Head of Textile Development. She discussed many interesting, new concepts and exchanged ideas about the latest trends, especially with international brand manufacturers.
Many of the visitors also took the opportunity to look around KARL MAYER’S Virtual Showroom using the mega-touchscreen.
An unusual contest was also attracting large crowds – a battle between two mini-robots, controlled by a textile remote controller, which the visitors could try out for themselves. The electrical control technology needed to produce this was incorporated directly into the textile during production on a jacquard raschel machine. The onlookers to this spectacle included fabric producers, as well as brand experts and end users. Most of them were from the sports sector, but many of them were also operating in the medical and protective clothing sectors and were looking for inspiration. Their interests were equally as wide and varied. “Some of them already had very specific product ideas, whereas our samples were the first time that some of them had encountered the concept of using textiles in the electronics sector,” says Sophia Krinner, a member of KARL MAYER’s exhibition team. In the near future, this textile product developer aims to follow up a number of contacts, with a view to taking concrete steps towards cooperation.
Since 01.02.2019 the new website www.Textile-Makerspace.com is online. With Textile Makerspace, KARL MAYER presents a platform for innovative, textile applications that have been developed using state-of-the-art technologies – keyword 3D Printing, Smart Textiles, Wearables & Co.
KARL MAYER is stepping up its activities in synergistically linking the textile sector with new technologies, and has launched a new platform, which can be found at www.Textile-Makerspace.com. The aim of TEXTILE MAKERSPACE is to bring together innovations from both areas. In this case, with its specialist expertise and networks, KARL MAYER sees itself as an intermediary and instigator. “The TEXTILE MAKERSPACE should make space for trying things out, for developing, and for innovative thinking – in the textile industry as a whole, but also in other sectors. In this case, the main focus is on exchange and interaction. We want to make contact, exchange knowledge and use synergies – in other words, we want to build our own community,” says Michael Kieren, one of the initiators of TEXTILE MAKERSPACE. The aim is to come up with new developments, some of which have already been set in motion. Smart textiles, wearables and 3D-printed garments have already been at the focus of trade fairs and other events for some time now. KARL MAYER started development work in this field last year with TEXTILE CIRCUIT.
TEXTILE CIRCUIT is the first topic to be covered by TEXTILE MAKERSPACE. It demonstrates the possibilities of incorporating electrically conductive yarns into warp-knitted textiles directly on the machine. Functional elements, such as sensors, conductors and coils, can be incorporated very easily, without any additional production steps or compromising the textile characteristics. This has led, for example, to the development of comfortable cuffs for controlling robots and textile charging stations for inductively charging smartphones. Michael Kieren, together with the Product Manager, Sophia Krinner, presented these types of systems for the first time at the specialist IDTechEx Show! in California, USA, in November 2018. The products being shown generated a great deal of interest. Michael Kieren sees a particular potential here for sportswear brands. The TEXTILE CIRCUIT and TEXTILE MAKERSPACE were also the topic of many conversations held at the leading trade fair for the sports sector, ISPO, which was held in February 2019 in Munich.
The subject of additive manufacturing is on the agenda for the next stage of the TEXTILE MAKERSPACE platform. The aim is to combine the possibilities offered by 3D printing with textile technology – in order to design and functionalise textiles individually. The impetus for bringing together new and traditional production disciplines at KARL MAYER was a workshop entitled, “Additive Manufacturing for the Textile Industry”. The event was held on 11 January 2018 at the company’s headquarters in Obertshausen. The concept was a great success. Another event will be held on 13 May 2019, the day before the Techtextil exhibition opens. One of the topics will be TEXTILE MAKERSPACE. Other promotional events for the platform are the next Techtextil fair in Frankfurt, but especially ITMA, which is scheduled to take place from 20 to 26 June 2019 in Barcelona.