KARL MAYER Textilmaschinenfabrik GmbH
Bühlstrasse 25
63179 Obertshausen

To hand ready-to-use solutions on a silver platter - KARL MAYER Textilmaschinenfabrik GmbH

Ready-to-use products save resources and are therefore right on trend, but they have to be developed and manufactured with great attention to detail. KARL MAYER’s DJ series of machines now offers even more scope when it comes to designing lingerie and clothing products. This machine building company has developed two new processes for producing seamless briefs, which show just how it’s done. More specifically, these innovations relate to processes for producing tubular fabrics, in which virtually all the elements of the final garment are incorporated during the warp knitting process. Cut-and-turn design: The first technique produces a tubular fabric, in which the contours of the final component are fully incorporated in the transverse direction panty by panty. A straight left hip seam, a U-shaped joint at the inner legs, and another straight, closed seam at the right hip are worked one after the other at right angles to the direction of fabric on the DJ 6/2 in a gauge of E 28. Even the waistband and leg bands and a dainty rose pattern in the abdominal section are also produced during the actual fabric production stage. The front needle bar of the Seamless Smart processes the front part of the briefs to produce the transverse design, while the rear needle bar works the back at the same time. Cutting lines are marked along the contours, and the knitting elements of the front and rear bars meet transversely to the production direction to join the two fabric halves together with flat seams at the hips and gusset. Tensioning bands are also incorporated on the left of the leg borders and right of the waistband, which are needed for fixing purposes. Once the component has been turned inside out, the briefs, which have been processed in the crosswise direction, are ready to wear immediately. The briefs can be produced very efficiently and they are also extremely comfortable to wear. The flat, directly integrated seams prevent any uncomfortable chafing. A specific blend of polyamide and elastane equalises any anatomical differences between the front and back. A stretch zone in the form of a string tanga also gives the bottom a rounded shape. Side-seamless design with shaping effect: The second new technique for producing briefs is also based on the principle of producing two halves, but the symmetrical aspects are different. The two parts of the briefs not only match the front and back parts of the body, they also correspond to its right and left side. In this case, the DJ 6/2 works the same lappings on both needle bars, sometimes separately and sometimes together. The main design elements of the briefs, i.e. the sections of the inner leg borders in the front and bottom areas that are to be sewn subsequently, the seam running from the gusset to the navel, and the anatomically shaped bottom seam, are thus produced in the transverse direction to the production direction.