The production of a complete garment in one piece, without any seams at all, and with an integrated body-mapping design - this is what KARL MAYER's double raschel machines with EL pattern gear and jacquard make possible.

WARP KNIT SEAMLESS

The KARL MAYER GROUP showed a chic example under WARP KNIT SEAMLESS with a sports dress that attracted a lot of attention at the ITMA. The trendy outfit can be produced on a DJ 6/2 EL or RDPJ 6/2 EL in gauge E 28 and offers all the performance features of functional sportswear: breathability thanks to open areas in exposed places, freedom of movement and fast drying. In addition, the feel is just right. The use of polyamide makes the fabric soft and supple. For precise elasticity, the jacquard bars were drawn in with a two-component yarn of polyamide core and elastane sheath. There was a lot of discussion in Milan, especially about the ready-to-wear set of top and leggings. Both parts only have to be separated from the manufactured panels. This saves sewing effort and waste. Depending on the size and cut, the amount of fabric to be disposed of is about 15% for leggings and about 5% for tops. In the case of tops, only the shoulders and neck have to be cut out; arms and torso are created ready to use directly on the machine. In addition to these advantages, "WARP KNIT SEAMLESS" technology offers the possibility of efficiently producing mass-produced items with customization, for example with logos, and items made to customer specifications.



INNOVATIVE FASHIONABLE 3D-SEAMLESS

Completely new seamless knitted fabrics offer an exciting look and a comfortable feel thanks to a clever combination of three-dimensional and open structures in a textile. The plastic pattern parts create extravagant irregular surface effects, in combination with very fine yarns for a soft feel and only partial contact of the fabric with the skin. They are created by the jacquard bars of the machine used, a DJ 6/2 EL or RDPJ 6/2 EL, each in gauge E 28. The jacquard bars process a polyamide yarn with an elastane sheath in alternating layers with long floatation, which creates plasticity by shrinking during finishing. The jacquard bars allow the design elements to be placed as desired. Another advantage is the almost complete production of the garment directly on the machine. Only a few processing steps are required until the finished part.

4D-KNIT - THE NEXT GENERATION OF SPACER

If the spacer layer of 3D knitted fabrics is filled with bulked yarn, previously unattainable performance features and surface designs can be implemented. Smooth patterns, two-color coloring, breathable mesh zones and - this is new - clearly pronounced relief parts, each with individual placements and dimensions, are possible. Depending on the amount of filling and the design of the plastic motifs, a wide variety of articles can be created. The product repertoire ranges from breathable goods, e.g. for functional shoes, to cuddly padded and warming jacket fabrics. When it comes to clothing with an insulating effect, 4D-KNIT articles score points with a decisive sustainability advantage over napped fleece fabrics: Fewer fiber fragments are carried into the water during washing, because the insulating fibers are enclosed between the outer surfaces of the 3D textile. This is confirmed by the results of a study conducted by Hohenstein Laboratories in Bönnigheim. The new spacer fabrics are produced on an RDPJ6 6/2 EL FB in gauge E 28.