Investigation of tailored in-situ texturing for the fabrication of elastic embroidered mesh structures

• Applicant: Dr.-Ing. Robert Tonndorf
• Subject Area: Plastics Engineering ; Lightweight Construction, Textile Technology
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 554398438

Mesh structures and textiles are characterized by low weight, high strength and a large pore structure. The use of stretchable yarns made of polyurethane or elastane enables the production of stretchable mesh structures whose pore structure is maintained under load. However, the use of these yarn materials is not always possible or desirable. There are currently no alternative technical solutions for producing a stretchable mesh that maintains its pore structure under load and does not consist of these stretchable yarns. The aim of this project is to investigate a novel and alternative solution to this problem. The approach described here is based on the idea that local elastic fiber reservoirs are created within the mesh structure that resemble the deformation behavior of stretchable yarns. These new mesh structures are realized by machine embroidery. The elastic fiber reservoirs consist of loop-shaped or meandering fiber structures that are produced by machine embroidery and heat treatment. The deformation behavior during loading is initially based on the pulling apart of the loop shapes of the elastic fiber reservoir. Since this process mainly deforms the geometric fiber shape, it is assumed that the deformation behavior of the elastic fiber reservoir is largely independent of the underlying fiber material. Since both the elastic fiber reservoirs and the complete mesh can be produced simultaneously by embroidery, it is assumed that these novel elastic meshes can be produced in one step. A mesh structure consisting of a large number of these fiber reservoirs would result in a deformable mesh structure without impairing the overlying textile structure during loading, as only locally limited parts within the structure are deformed. The work packages specifically include the following objectives: The first objective is to investigate the deformation behavior of the elastic fiber reservoirs. The independence of the elastic behavior from the fiber material used is analyzed. Subsequently, computer models will be generated in order to virtually reproduce the deformation behavior of the elastic fiber reservoirs. Finally, the combined production of fiber reservoirs and mesh structure is investigated.

• DFG Programme: Research Grants