New Generation of Spacer Textiles: With 4D-KNIT, KARL MAYER has Redefined Warp Knitted Spacer Fabrics



4D-KNIT articles in a new gauge offer style, lightness and a soft touch

Dissolving design boundaries

Thanks to 4D-KNIT, KARL MAYER has redefined the notion of warp knitted spacer fabrics. The term represents a completely new generation of spacer textiles that are based on the basic construction of conventional 3D warp knitted fabrics, but that significantly deviate from traditional designs. The spacer layer is particularly different: the space between the upper and lower can be filled with bulked yarns to achieve unprecedented effects in performance and design. In addition to a smooth pattern, two-tone colouring and breathable mesh zones as before, the two surfaces can have clearly pronounced relief designs – each with individual placements and dimensions. Depending on the amount of filling and the design of the plastic motifs, a wide variety of pieces is possible, from cosy padded jacket fabrics that keep you nice and warm in winter to breathable textiles for functional shoes, for example. The new warp knitted spacer fabrics are produced on a RDPJ 6/2 EL FB, previously in gauge E 24. To further explore the potential for the sportswear and outerwear sector, KARL MAYER’s textile product developers have produced the first 4D-KNIT products on a jacquard double needle bar raschel machine in E 28.

New expression of fabrics for sports and leisure

4D-KNIT.SOLUTIONSDouble Needle Bar Technology is opening a new chapter by offering from now on, besides the usual 3D-Spacer fabrics, also new 4D-KNIT.SOLUTIONS produced on our RDPJ 6/2 EL.A clever bar arrangement and technical configuration combined with our established high quality KARL MAYER Piezo-Jacquard technology, enabling this innovative double needle bar machine to open up a new dimension: producing fabrics with diverse malleable patterning on both fabric sides. The 3D motives can be completely variable in shape, positioning and height. Small and flat reliefs or deep and bulky forms with cushioning are possible. Further, the design can contain freely placed holes, for even more possibilities. The openings can be used for directed air flow or lighting effects.The well known and much valued pre-engineering of the fabric is also possible. Even complete seat covers of various shapes can be designed in one piece, just as an example of the creative freedom.

4D-KNIT fabric with holes

Machine: RDPJ 6/2 EL FB
Gauge: E 24
Article Number: Article 2019/091

The double needle bar machine RDPJ 6/2 EL with Piezo-Jacquard technique creates a new dimension, which leads to a new level of design potential: A huge variety of fabrics with pronounced plasticity on the face side. The 3D motives can be freely designed in shape, placement and thickness. This fabric example here shows a highly raised pattern combined with breathability holes. The breathable areas combined with a high cushioning effect make such fabric – with the appropriate yarn – applicable for upholstery in the home interior or automobile industry.


Benefits of 4D-KNIT.SOLUTIONS of RDPJ 6/2 EL:


4D-KNIT fabrics offer a new level of design potential. Use small and flat reliefs or deep and bulky forms with cushioning

4D_KNIT_2 High range of fabrics and applications

The RDPJ 6/2 EL can produce different kind of fabrics, to adapt to varying market situations: 4D-KNIT, double layer fabrics, standard spacer and jacquard patterned spacer. Suitable for various applications such as automotive, shoe fabrics, home textile, outerwear, mattress and many more.

4D_KNIT_3 Design Possibilities

  • 3D forms and patterns at front and back side, holes, any kind of design possible
  • Use of different yarns for colouring and shaping effects
4D_KNIT_4 Resistant

  • Robust and made to last fabric properties
  • Over 20.000 abrasion cycle tested: no sample destruction
4D_KNIT_5 Productivity

Much higher productivity than other knitting technologies, with similar fabric appearance

Material processed in a gauge of E 28 is commonly used to produce fine elastic sportswear items. Skillfully threaded-in on the machine, the result was a fabric that weighed significantly less than its E 24 counterpart and felt soft to the touch. What’s more, the functional chic design hits just the right mark. With its two jacquard bars, the RDPJ 6/2 EL FB makes the front side and back side of the top as a single piece with fashionable 3-dimentional bulky form – including every sophisticated design detail. These include contours to mark the cut edges, flat bars for segmentation, open mesh parts and underpadded relief patterns with small-format geometric motifs. The small repeat of high-low effects reduces the fabric’s contact area on the skin and therefore minimizes any unpleasant stickiness caused by sweat, while perfect thermoregulation for sport and leisure is ensured by breathable mesh areas with sufficiently large openings, and built-in elastic zones offer freedom of movement. Yuji Yamamoto, Regional Product Owner for double needle bar raschel machines at KARL MAYER, wants to use the new series to appeal primarily to fashion and sportswear manufacturers. “The apparel sector in particular can benefit enormously from these new 4D-KNIT fabrics. The low weight and soft feel guarantee a high level of wear comfort, and the yarn material in the spacing also offers good insulating properties with extremely low discharge of microplastic particles, since we do not use brushing or raising processes,” explains the textile specialist.

Contact details:

KARL MAYER Textilmaschinenfabrik GmbH . [email protected] . www.karlmayer.com
Brühlstraße 25 . 63179 Obertshausen . Germany . T +49(0)6104 402-0 . F +49(0)6104 402-600

Share This