3D Weaving

Dimension Convention in Textiles

One Dimension
Fibre & Yarn
Two Dimension
Fabric
Three Dimension
- Garment

Dimension Definitions in Fabrics

2D fabric

: Constituent yarns are

disposed in one plane

2.5D fabric : Constituent yarns are

disposed in a two
mutually perpendicular
planes
3D fabric

: Constituent yarns are disposed

in a three mutually
perpendicular planes

3-D Woven Construction

Y

A single-fabric system, the constituent yarns

of which are supposedly disposed in a three
mutually perpendicular plane relationship

3-D Construction
The 3D Woven fabrics
are defined as:A single-fabric system, the
constituent yarns of which
are supposedly disposed in
a three mutually
perpendicular plane
relationship

2 D Structure
Yarns

laid in a plane

Thickness
Single

is small

layer design

Plain,

Twill, Satin etc..

Used

in laminating

Drawbacks of 2D structure
Anisotropic
Poor in-plane shear
resistance
Less modulus than the
fibre material due to
presence of crimp

Remedial Measures
Reduction of crimp in loading direction
Use of high modulus yarn
To increase isotropy or shear rigidity or
bais properties
Triaxial weaving can be used

Structural Analysis
C

Load

Yarn extension
regon

Decrimping region
Inter-fiber friction
effect

Extension

Decrimping zone is completely absent in UD

fabric and very little found in 3D structures
Small amount of crimp is mainly due to the
fact that the samples are produced on 2D
weaving machine

Tri-axial Weaving
Three

yarn systems interlaced at 60

OS and OZ warp thread
W is weft thread
H is width
S is height

Tri-axial Weaving
Three

yarn systems interlaced at 60

Loose

Compact

Multiaxial Weaving
Dimension stable in any
direction
Isotropic distribution of
stress forces
Uniform strain behaviour

3D Weaving
Yarns are arranged
perpendicular to each other
in X, Y and Z directions
No interlacing or crimp
exists between yarns
Fiber volume fraction is
between 45 and 55 percent

What is 3D weaving?

Making of fabrics with substantial thickness by layering

Shedding and weft insertion horizontally and vertically.

Technical textiles made on 3 planar geometry.

Why 3D weaving ?

Woven construction for reinforcement

structure

2 D Structure

3 D Structure

2D Vs 3D Weaving

One pick per loom

cycle
Unavoidable crimp

Multiple pick per loom

cycle
No internal crimp

Limited thickness

Greater thickness

High production
speed

Very low production

speed

Weaving process
Process type

2-D Weaving

Designed to interlace two

Orthogonal set of yarnsBasic
(either single or multilayer
warp and a weft)

3-D Weaving
Designed to interlace three

functional design
Orthogonal set of yarns

(A multilayer
warp and two set of weft)

Warp displacement
In the fabric thickness
In the fabric thickness
direction for shed formation
direction
and fabric width direction
Mono-directional
In the fabric width
direction

Single
Single

Shedding
operation type

Shed
location

In the fabric width and

fabric thickness direction

No. of shade formableMultiple

Pick insertion

2D (sheet like and tubular)

Fabric
2.5D(pile/terry), 3D(solid)

Conventional 2D
weaving device

Dual-directional

Multiple

3D fabric (solid and tubular)

type producible

Device type

Special 3D weaving
device

Classification of 3D
fabrics
I) Based on type of 3D Structures

3D Solid:
Multilayer
Orthogonal
Angle interlock

3D Hollow:
Flat surface
Uneven surface

3D Shell:
By weave combination
By differential take-up
By moulding

3D Nodal

II) Based on type of process

3D Woven
3D Knitted
3D Nonwoven
3D Jacquard design
Braided structure
III) Based on type of weaving
process
2D weaving 3D fabrics
3D weaving 3D fabrics
NOOBING

3D woven sandwich fabrics

Connected by orthogonal
threads resulting in a textile
ssandwich preform
Production of 3-D fabric is
based on velvet weaving
technology
Velvet is produced by cutting
the connecting threads between

High damage tolerance

Extremely high
delamination resistance
Consists of two layers ; the two
Able to contain functional fabric layers of a 3-D fabric
foams
High and well-distributed
energy absorption

3D Solid structures
Multi-layer

Multi-layer structures are distinguished by the

individual layers
Each layer may be of different weave
Stitching of layers
Structure ranges from 2 to 4 layers

3D Solid structures
Orthogonal

It is characterized by straight yarns or yarns

sections in warp, weft and thickness directions
This structure can provide a greater volume
fraction than angle interlock structures

Angle Interlock Fabrics

It is a multilayer fabric
Used for flat panel
reinforcement
Normally woven on a
shuttle loom
Warp yarns taken directly
from a creel

Special 3-D structures

3-D hollow structure

3-D shell structure
3-D nodal structure

3D Hollow structures

3D Shell by uneven take-up

3D Shell by mould

Nodal Structure

3D by Stitching Operation

Limitations
Dimensional stability, conformability and mold ability
To withstand multi-directional mechanical
Required interlaminar strength and damage tolerance

3D fabric on 2D Weaving System

Multilayer structure weaving

True 3D Weaving

TRUE 3 D WEAVING PRINCIPLE

Dual-directional shedding operation

True 3D Woven Fabric

Warp

in Z direction and
Two mutually perpendicular weft
in X & Y

Orthogonal view

Structural Advantage of 3D
Apart from substantial
thickness (3D) the fabric
has a yarn in z direction
A single-fabric system
and an integrated
structure

Characteristics Advantage
Dimensional stability
Conformability
Mold ability
Withstand multi-directional mechanical stress
Interlaminar strength and damage tolerance

Cost Advantage
Composite Manufacturing is
comparatively cheaper
Quick, easy and cost-effective highperformance solutions

Performance Advantage
Delamination resistance
Compression resistance
Impact resistance
Long life

Application Advantage
Customised Profile structures
Wide range of cross-sectional dimensions
Load-bearing structures can be made

L Profiles

Pi profile

T Profiles

U Profile

Assembly of profiles

Can be used in Modular construction

Applications of 3D fabrics
The main current applications of 3D woven
fabrics are in :
Composites made from textile preforms
Protective clothing

Composites made from textile preforms

Automobiles
Aerospace
Marine

applications
Civil engineering
Machine components
Sporting Goods
Structural Engineering
Wind Energy

Automobile applications

In last 30 years total material in air

craft (on weight basis) has gone up
from 15% to 75%

Space programs

Marine applications

Civil Engineering

Machine Components

Sheet of carbon fibre

prepreg

Large

Aerospace parts
Vacuum-bagged part for oven

Structural Engineering

Products &
Equipment

Pipes

Pressure vessel8 m dia. Chimney stack

Lathe
Racetrack
Whirling-Arm

Sporting Goods
Sporting
Goods

Wind Energy

Wind energy currently contributes 1.5 %

of world energy need. Growth by 2020
to 21-30%.

Protective Clothing
Body armours
Ballistic Protection
Cut resistance fabric
Bullet proof shoes

Ballistic Proof Clothing

58

Upper Arm Ballistic Protection

Ballistic helmet

Bullet proof shoes

Anti-riot Shield.

Challenges
3D Weaving Machine

Primitive 3D Weaving Machine

3D Weaving Machine at NCSU

Greenwoods patent : USP 3 818 951

Khokars patent : SE 509 944

Japans patent
TOYOTA developed a 3D weaving
concept in a research project funded
by METI
Commercial machine yet to come

Multi weft insertion 3D weaving: under

development at Manchester(UMIST)

3D weaving in IIT Delhi