Karl Mayer, a leading textile machinery manufacturer, has introduced revolutionary innovations in seamless knitting technology. Their double-needle-bar raschel machines with EL pattern drive and jacquard enable the production of complete garments without any seams, combined with integrated body mapping designs. This cutting-edge technology, known as Warp Knit Seamless, has already captivated audiences at the recent ITMA 2023 exhibition.
One standout example is a stylish sports dress that showcases the capabilities of Karl Mayer’s Warp Knit Seamless. Made on their DJ 6/2 EL or RDPJ 6/2 EL machines with a gauge of E28, this sports dress offers exceptional performance features such as breathability, freedom of movement, and quick drying. Its soft and supple fabric, achieved through the use of polyamide, ensures a comfortable fit. The incorporation of a two-component yarn, consisting of a polyamide core and elastane sheath, provides precise elasticity.
Apart from its functional advantages, the Warp Knit Seamless technology greatly reduces sewing effort and waste. By cutting out the garment elements from the manufactured panels, the amount of fabric to be discarded is minimized, typically around 15% for leggings and 5% for tops. This technology also enables mass production with customizations, including logos, catering to individual customer requests.
Another breakthrough from Karl Mayer is the development of innovative fashionable 3D seamless fabrics. By combining three-dimensional and open structures, these fabrics offer a unique aesthetic appeal and a comfortable feel. The jacquard bars of the DJ 6/2 EL or RDPJ 6/2 EL machines, with a gauge of E28, create irregular surface effects through plastic pattern parts, while fine yarns contribute to a soft handle. The garments can be produced almost entirely directly on the machine, requiring only a few processing steps to achieve the final product.
Additionally, Karl Mayer introduces the next generation of spacer fabrics with their 4D-Knit technology. These fabrics, produced on the RDPJ6 6/2 EL FB machine, provide enhanced performance features and surface designs. By filling the spacer layer of 3D warp-knitted fabrics with bulked yarn, various textile solutions are possible, including breathable fabrics for functional shoes and cozy padded jacket fabrics. The insulation fibres in 4D-Knit articles also exhibit superior sustainability compared to napped fleece fabrics, as they release fewer fibre fragments into the water during washing, thus reducing environmental impact.
Overall, Karl Mayer’s advancements in seamless knitting technology offer exciting possibilities for the textile industry. These innovations not only enhance performance and comfort but also contribute to sustainable and customizable garment production.
