3D Fabrics / 3D Weaving

Dr. Zuhaib
Ahmad
Department of Materials and Testing
National textile University,
 Learning Outcomes

At the end of this Module, you will be able to understand:

• What are the 3D Fabrics?

• 3D Fabrics types, applications and weaving

 3D Fabrics
• There are various manufacturing processes for the interlacement of yarns
to produce three-dimensional (3D) fabric structures as preforms for textile
composites.

• The manufacturing route is determined by the end-use of composites

and therefore the composite industry does not solely rely on one
method but a selection of methods for fabric formation.

• There are many different views on what 3D woven fabrics are, but one
common understanding is that 3D fabrics must have substantial
dimension in the thickness direction formed by layers of fabrics or yarns.
Types of 3D Structures
Classification of textile reinforcement structures based on axis and dimension
 3D woven fabrics
• 2D woven 3D fabrics
• These fabrics are woven on conventional weaving
machines using the principle of multilayer fabrics. Only
one weft insertion device is used on a single height level
to weave these fabrics. E.g., single shuttle, single rapier.

• 3D woven 3D fabrics
• These fabrics are woven on modified weaving machines.
Multiple weft insertion devices are used on multiple
height levels to weave these fabrics. E.g., the fabrics
developed by Fukuta and Muhammad.
 3D Fabrics
Three dimensional fabrics are those
fabrics which have substantial
measurements in three directions.

3D fabric
2D fabric
 3D Fabrics
The 3-D fabrics are defined as “A
single-fabric system, the constituent
yarns of which are supposedly disposed
in a three mutually perpendicular plane
relationship”.
 2D Versus 3D Weaving
Interlaced
3D fabric

Vertical binder yarn

2D Weaving
3D Weaving
- One pick insertion - Multiple pick insertion
per loom cycle per loom cycle
- Unavoidable crimp - No internal crimp
- Limited thickness - Greater thickness
- High production speed - Low production speed
• 2D woven 3D fabric
Types of 3D solid structures
 Mechanical Advantage of 3D Woven Structure

Three-dimensional (3D) woven composite has high

stiffness, strength, and energy absorption capacity
along X, Y, and Z directions because there are no
crimps in yarn.
 Potential Applications

3D fabrics can be used for the production of specialty

industrial fabrics for making preforms for :
•Automotives
•Ballistic
•Marine applications
•Sports goods
•Construction
•Various industrial applications
 Applications of 3D Composites

The main current applications of 3D woven fabrics

are in composites and in protective clothing.

• Helmets
• Foot wear
• Backpack straps & backing
• Seat cushions
• Protective vests
• Military gear etc.
Manufacturing Methods to
Produce 3D Fabrics
Multilayer Principle
Orthogonal Principle
Angle interlock Principle
Dual-direction Shedding Method
By Stitching Operation
 The Multilayer Fabrics
• The manufacturing of multi layer fabrics is the very first step towards the evolution
of 3D-woven preforms. Perhaps the very first idea of such a fabric comes from
Fetterly who developed a thick woven fabric in 1910.

US Patent: 975940, (1910).

• 3D fabric manufacturers like 3tex (USA) used the same 100 years old
technique to weave their most modern bullet proof glass fabrics.
• 1/2 inch thick glass composite is capable of defeating NIJ threats
Level III (six rounds of 7.62 mm M-80 NATO ball ammunition).

Fabric developed by
Mansoor Muhammad
US Patent: 6315007, (2001)
National Institute of Justice (NIJ) standards
 3D Weaving machine
Fukuta was perhaps the first person to develop a weaving machine for a real
3D-fabric in which yarns were laid in 3-axes i.e., X, Y, Z
US Patent: 3834424, (1974)
 Mohamed developed a machine for weaving a 3D fabric with 5-
axes. US Patent: 5465760, (1995)
• x direction 12
• + 45 x direction −18,+18
• y direction 14
• z direction 16
Weft

Warp

Warp not aligned

weft not aligned
Warp crossection weft crossection

• Warp above
each other
• Weft above
each other
2D woven-3D fabric : weft cross-section at binding thread

2D woven-3D fabric : warp cross-section

Multiple
insertion in
3D woven- 3D
fabric
 3D Orthogonal Structure

Yarns lie perpendicular to each other in X, Y and

Z directions
No interlacing or crimp exists between yarns
Fiber volume fraction could be between 45 and
55 percent
Require specialized weaving machines
Development of Suitable
Arrangement on Loom
Binder Warp

Heald
3D Fabric Frames
Produced

Ground
Warp

Reed
Definition:3D Orthogonal fabric
• Reinforcement yarns are
arranged perpendicular to each &
other in X,Y Z direction

• No interlacing between yarns

• Fibre volume fraction is 45-55%

 Multilayer 3D woven preforms
The Multilayer Fabrics are divided to 4 major categories,

• OPEN WIDTH FABRIC: The idea behind the open width fabric is to
make a fabric of greater width than the nominal weaving machine
width. With this concept a fabric width of 2, 3 or even 4 times can
be made on a normal weaving machine.
• The end use is the same as single layer fabric but for wider
applications

• TUBULAR FABRIC: The fabric is formed in the shape of a tube (as

seen through warp corssection), end use is circular fabric, sacks etc
 Multilayer 3D woven preforms
• STITCH MULTI LAYER FABRICS: The appearance is like a single layer
fabric but actually it is a multilayer in which a number of layers are
stitched together during the weaving process.
• These are the fabrics which gives rise to the concept of 3D
woven performs for textile composites.
• In this way a 3D fabric can be made in a two-in-one process e.g.,
weaving along with stitching which eliminates the need of
stitching process after weaving, saving time and cost

• MULTI PLANE FABRICS: In such fabrics two or more

layers alternatively change their positions
 Recommended Books/Sources

1. Hand book of weaving by Sabit Adanur, 1st (2000), CRC Press

2. Principles of Weaving by Marks and Robinson, 1st (1976), The Textile Institute.

3. Woven Textile Structures by B.K. Behra and Hari, 1st (2010)

Woodhead publishing

4. Research Article and YouTube videos

Stay Safe and Healthy