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Ilkay Özkisaoglu

Since 04/2021 229 Episoden

#228 Karl Mayer Technical Textiles Explained | Warp Knitting, Raschel & Multiaxial Machines

28.05.2026 41 min Staffel 5 Episode 186

Zusammenfassung & Show Notes

In Part 2 of our deep-dive at the Karl Mayer Textile Innovation Center in Obertshausen, Ilkay Özkisaoglu is joined by Jürgen Trötzsch (Project Manager Machine Specials) to explore the fascinating world of technical textile machinery.

This episode goes beyond materials and dives into how advanced warp knitting technologies enable high-performance applications across industries—from composites and infrastructure to medical and filtration systems.

🔍 What you’ll discover in this walkthrough:

👉 Multiaxial Warp Knitting Machines (Non-Crimp Fabrics)
We start with the backbone of composite reinforcement: multiaxial fabrics. Learn how fibers are precisely oriented (0°, 90°, ±45°) to create high-performance reinforcements used in automotive lightweight structures, sandwich panels, and pultruded components.

👉 Raschel Machines with Weft Insertion
A key technology in technical textiles: Raschel machines allow the integration of additional yarn systems. With weft insertion, fibers are laid in a controlled, perpendicular orientation and then stitch-bonded—enabling precise mechanical performance and tailored functional textiles.

👉 Handling Sensitive Functional Fibers
Discover how Karl Mayer machines process delicate fibers such as hollow fibers for filtration and medical applications. These systems operate at extremely low tensions to preserve fiber geometry and functionality—critical for dialysis, oxygenation (ECMO), and advanced filtration.

👉 Tricot Machines – The Core of Warp Knitting
Understand the fundamentals of warp knitting with tricot machines, where multiple yarns are knitted simultaneously to create flexible, durable fabrics used in applications ranging from apparel to camouflage textiles.

👉 Specialized Machinery for Filtration & Medical Textiles
We explore how aligned fiber structures are produced for filtration cartridges, enabling precise control over spacing, density, and flow characteristics—opening opportunities in water treatment, healthcare, and beyond.

👉 Laboratory & Modular Innovation Systems
Inside the Innovation Center, Karl Mayer showcases flexible lab-scale machines used for customer trials. These systems allow rapid prototyping—from fiber spreading and coating to winding—bridging the gap between idea and industrial production.

👉 Investment & Market Trends
What does it take to enter the technical textiles space? Jürgen shares insights on machine investments (€500k–€1M), long lifecycle performance, and key growth areas such as medical textiles, filtration, and functional composites.

💡 Key takeaway:
Karl Mayer is not producing textiles—they are engineering the machines that enable entire industries. Their technologies sit at the very beginning of the value chain, shaping the performance of products that follow.

🎯 This video is for: • Composites & advanced materials professionals
• Textile engineers & manufacturers
• Investors exploring technical textile markets
• Anyone curious about the machinery behind high-performance fabrics

📍 Filmed at: Karl Mayer Textile Innovation Center, Obertshausen (Germany)
👉 Stay tuned for more deep dives into warp knitting, composites, and industrial innovation.
#technicaltextiles #WarpKnitting #KarlMayer

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YouTube Episode: https://www.youtube.com/watch?v=7OJc5AGe2l8

Transkript

So wonderful. Good morning dear LinkedIn Community, Composites Lounge members and technical textile experts out there. I have now the honor today at the first day of the Textile Innovation Center with Karl Mayer at Obertshausen, their headquarter? This is the first hour of the Innovation Center. And together with me now is Jürgen. I met Jürgen at JEC just a couple of weeks ago, where we were talking about the Textile Innovation Center, and now it's here. Finally. Yeah. Finally. -Finally. It's here. Finally. It's open and very clean environment. lots of machine and we will walk you through this. But I would like to start with Juergen now about the technical textiles of Karl Mayer. As you know, Karl Mayer has a different business units warp preparation, for example, technical textile. And the third one. -Warp knitting. Warp knitting. Yes. And we will walk through all of them because you guys, you know, on my head there is composites and technical textiles. But of course we will be looking also around and widen the horizons for you guys. But we will talk about technical textiles first. So let's walk through this Jürgen. We will start now immediately with carbon fiber right. We are seeing our bonnet here. -Yeah. So as mentioned this is now our brand new Textile Innovation Center. And it shows the huge variety of warp knitting technologies. So and of course one is the world of technical textiles. And understanding warp knitting for technical textiles starts with understanding composites. So what we are producing are so-called non-crimp fabrics or multiaxial reinforcement. And I think. Let's get this in the picture. -The this is one of the most typical known some automotive applications you have in carbon fiber multiaxial, which can be used for structural parts, for lightweight, for of course sports application to use it as for example this cover for yeah the structural part of a high performance car. But of course it's not a one and only. So reinforcement means to save weight, to be on a, on a lightweight level, to be sustainable. There can be other other applications in automotive can be for example sandwich panels for some housing can be something for caravanning. For example, can be pultruded parts which can be used in under the floor for carrier for batteries for example. And it, it shows here what is the benefit of multilaxial reinforcement. For example, if you don't have reinforcement only in one direction with a multiaxial fabric, you are flexible to have fibers in different orientations, typically +/-45 degrees or 0°/90° degrees. are the fibers in our non-crimp fabrics? -So the beauty of this bonnet is really that you see the structure of the carbon fiber, right? Yeah. So you have used a very thick towel here as it looks like. Yeah. Is this by purpose or just to demonstrate to tell is a demonstrator right? -Yes you know that unfortunately I would say woven fabric is the typical for how to see class A surface which you want to have visible. But with the multiaxial and this is I think more and more also in the application it shows a different structure and you have more variety in playing with the fiber integration of the carbon fibers, but also with the knitting yarn with the warp knitting yarn. Inside it can be colored, it can be red, can be white. So you can make different applications and it makes it, I think, quite interesting also for visible parts in fiber reinforcement. -Absolutely. It gives you a totally different flavor. So this is the rear of a seat. So of course we can also have an or have in automotive applications grids and nets which can be used for protection within a car but can be also in airplanes for example, everywhere where you will need the impact protection fromfor example the inside interior or the people. So reinforcement is not only fiber reinforcement of course. You know we have also applications as you can see here in our next application area. So-called reinforcement in civil engineering can be a fiber reinforced concrete, but can be also, for example, for streets, for the reinforcement of streets, which is especially in our climate area. You know, we have always problems with our streets between winter and summer period. You have water within the concrete. You have then sometimes frozen period. And you get problems with cracks inside of the concrete. And for example, this can be such an reinforcement application you can use there. Yeah. So it's quite stiff. So you have already some. Some coating or. -Some coating on this. Yeah. It's not a matrix. It's a, it's a coating to get a better bond with the asphalt. -Yeah, exactly. This is it. So this is also, of course, sometimes the coating with asphalt already in the grid. And then you have, as you mentioned already, better bonding to the asphalt of the street. And you got this is a black carbon or just the, the the bonding is black. Right. -Exactly. So normally and then you got also very lightweight and open structures. -Exactly. So this looks more like a bio. Is it. -Totally. Right. This is can be flex or even hemp fiber. And this brings us directly to the to the next application. Technical textile is also used for so-called vertical greening. So you can use it as a structure for some plants wants to grow. And this can be used for vertical cleaning within cities to have a better living quality, to have more green inside. And this is not an reinforcement anymore, but it's also an grid you can use for civil and civil applications. Civil engineering application. -For our viewers. You can just walk us through you. You got this layers. So you got the soil, you got the stones and then you got the asphalt. Yeah. Where exactly would you now place the reinforcement. So the reinforcement is on the how to say on the, on the upper third. Yeah. Upper third 2 to 3cm then you have a asphalt everything you have to in the, in the upper layer. Where basically the load is the heaviest. -Exactly. It's special especially where you have the highest bending. Yeah. If, if there is some load on from a heavy car or heavy truck. -And does it impact somehow the, the hardening of the asphalt does not foster it. So no impact at all. Yeah. Of course, as we mentioned before, you need a good bonding between the textile and the asphalt. If this is then you have really good reinforcement without any disadvantages. Okay. And if you look here you see also now below the stones. Now this is a different application. It looks like right. This is not the asphalt. This is now also the soil. So you are separating the soil from maybe the natural soil to the one that is functioning. Right. -So this is a typical function you use in geotextile if you want to reinforce some walls if you have -Like to secure and sustain the foundation. Yes. -So you have foundation you need for example in water basins for different application even protect the shore on the sea. And you want to have a like to say a protection between water based soil and dry soil. So to help that you don't have any erosion in geo applications. So just as a is a short wrap up. So we have seen the automotive industry, the community with the classical visible carbon parts. Now the astonishing part. It's not a woven fabric. It's a multiaxial in that case. And then we see a heavy construction infrastructure application here that can be done with technical textiles. So what do we have here now what comes evident is we are moving now to defense applications. Right. So what is this about. -Yes. Step by step we are going now from reinforcement textiles to let's say technical textiles for agriculture as we had before already for for landscape architecture, even vertical cleaning. And one we also have what often is not known typical application for warp knitting technology are fishnets or agricultural nets you need for harvesting. But unfortunately, we are living in a world at the moment which has some military conflict. The same nets are also now used, for example, for protect streets from drons. So-called drone nets can be used to protect against military impact from drones. Yeah, this is unfortunately but it's useful application at the moment. Which 1 to 1 is the same net you can use for this. Yeah. So basically the rotors they catch into that fiber. And by that your drone becomes neutralized. Right. Exactly. -So as they say in the defense. You know, community sometimes you always ask, why should a white fiber be colored in a, in a color? Now, I was, Jürgen, a couple of weeks ago, at Diamond Aircraft in Wiener Neustadt, and I was seeing this engine there, and they had blue and red pipes. And I was asking the, you know, quality manager there, why is that blue and why is that red? I mean, it's common sense. Blue means cold and red is hot medium. It could be hydraulic or water or something like that. So in that case, what came to my mind is so in application where you have called, you just just use the blue one where you have hot, you use the red one. If you have something like sun, you use a yellow one and things like that. So it makes also sense for security reasons to color code textiles. Yeah. And this is a very typical textile application in dyeing them in different colors. Exactly. And many times critics say with technical textiles is difficult to do. But as we can see, it's not so difficult. It's possible. -Yeah. Of course, normally you produce grey fabrics and then go into finishing coloring. Yeah. And it depends on the fibre type but the coloring is not a topic anymore. So that's. -All right. Then we continue with defense. Yeah. So for protection last but not least, you can use of course. Also not automatically warp-knitted, but can be warp-knitted fabric for protection vests where you can use aramid fibers. Even ultra high molecular weight PE. So the inserts your insert in the vest made from these fibers and this is a typical application. I mean there is standard international standard for such protection inserts. And you have to withstand some impact velocity, some impact rate. And this often is made by aramid fibers or ultra high molecular weight PE, because it must be on the one hand it must be a lightweight. It should be still have some flexibility for wearing. And of course it should protect you against the impact. Yeah, I'm totally excited and enthusiastic because still my jacket holds this piece inside. So it covers basically my lungs and my heart. -Yeah Basically. -So this is one of an application we are also on and -This is sealed. So you cannot open this. Yeah. Because it must be protected against. The. -Problem. Water and even also um ultraviolet sunlight. Yes. Yeah. So if need be you can replace this. -Yeah. Off you go. Yes. -Okay. We have a trouser here. -Yeah. So this is then not the protection in its basic application, but of course we also have this for producing camouflage optic with application in military. Jürgen, tell our community who is probably not so iterate on tricot machines. What is the speciality of a tricot? Jürgen, tell our community who is probably not so iterate on tricot machines. What is the speciality of a tricot? -So a tricot machine is how to say this the main application of warp knitting. So in the most applications we talked before and multiaxial you use the warp knitting yarn for stitch bonding of the layers. But original warp knitting means to produce a tricot within the system of warp yarn where you have many, many single yarns you knit together. So this is the the big difference to a normal knitting. So in the warp knitting you have many, many, um, single yarns within one, one needle chain. And you, you knit them together. Yeah. And then you have a huge variety of how many of these warp knitting yarns you are using. We have normally one, 2 or 3, even four bar machines where we can produce such a fabric. -Okay, so you can thank you so much for the first impression. So this area is called the inspiration area. -Yeah. This is our textile showroom where we show the world of application for warp knitting. Yeah. So last but not least, one of our application is in health and medical application, which is a so-called cartridge for filtration, a filtration membrane made out of hollow fibers. And we can handle on our machines these hollow fibers to make a fabric. All the hollow fibers are then aligned parallel with a distinctive distance between each other. And so a gas or even blood can go through the fibers or along outside the fibers can be used for oxygenation to enrich blood with oxygen even can be used for dialysis and this application then on the next step I will show you the machine. So community Karl Mayer is not a producer of these garments. Karl Mayer is not the producer of the fabrics and the cloth. Obviously they are a machine producer. Just to to make that clear. And this textile innovation center has a few machines and also some are dedicated for technical textiles. And Jürgen shall we have a walk around those machines. Yes, sure. And this is the strike force. Bulletproof. And as Jürgen knows, I'm always curious to know how these things basically start from the beginning. So Jürgen. Now, we have dismantled this. This was actually sealed off to protect against UV light and water. Now, if we open this, now comes a very thick kind of material. What's that about? -So this is now exactly what we can produce on our machines. Um, these are an system of up to 70 layers of so-called ultra high molecular weight PE fiber. So this is, you know, it is polypropylene, but a special polypropylene fibre is a PE pe fibre. -Fibre. Polyethylene. -You said it's 17 layers. 70 up to. -70. Layers seven zero and one layer is about 10g/m². -20g. 20g. -20g. It's not bad, my guess. -Yeah. It's in combination of high strength polyethylene fibers in a so-called cross ply laying sequence . So we have zero and 90 degrees. -Oh, okay. So this is the other. -This is the length vertical. And then the next layer is indeed horizontal. Okay. And yeah we have a combination of these fibers with some polymer matrix. It's a film. Sometimes the fibers are also coated with a special PE wax for example. But the very beginning is the fiber coming from a creel. And as you can see, all the fibers are aligned in parallel. And with this lab machine here we can for customer tests for customer sample production. We can spread these fibers to one really thin fiber layer all fibers aligned in one direction. As you can see here, we have all the fibers in the single layer in one direction and coated by one side. This is a film of such PE wax. -Just for context, one more time. This is a laboratory demonstrator machine. We have seen these machines way bigger than this. Yeah, this is just because this is the Textile Innovation Center, which you should come and see actually yourself. And certainly the configuration is flexible here. So you can adjust it and do things like this. Yeah. Yeah. Exactly. So this is exactly what you mentioned, this, this Textile Innovation Center which does not show what can be done in the world of warp knitting, multiaxial laying and so on. But of course we invite our customers. Come see, get some ideas, some inspiration. In the next step can be, ah we want to test something new? And this is why we have also such laboratory scale machines here. So and we have here a modular system. We can spread the fibers. We can coate the fibers. We can of course then wind the fibers to make such samples. And the next step is then go to a prototype machine together with our customers. And then step by step go to the market. This is of course what innovation makes. And to bring it into the market. Now that may not now be your product here just for our converting community, I have here also a foil. As you know, we are also in the converting industry role good materials. And we will be there at the Hamburg summit again soon. So this looks also like a PE. -Yes. Foil it's some sort of translucent and then we have a foam inside. -This is some polymer foam. This is again For impact Energy absorption. Okay, so the bullet comes here then this foil may be preventing this impacting the foam too much. And the foam basically dampens the movement further so that if the bullet comes the person, it doesn't feel hurt. -Exactly. It sticks here, but also against the trauma and the deformation exactly. This is the size 200 by 300, and it's weighing 500g. It's not so heavy. No. -Good. This is why we use this very light fibers that you have also a wearability. It's not too heavy. -You can move. It's more. -Flexible. Do your job as a policeman or security officer or whatever. Okay, cool. So now let's dive into the machines of Karl Mayer, the technical textile machines. And yeah, this first part of the machine inspection with Jürgen is about also educating you guys. And because I also don't know and I admit that I don't know everything about textile machines. Get us on the fundamentals of the Raschel technique. -Yeah. So what means Raschel technique? Normally our warp knitting machines have two different knitting heads wemake for normal applications. This is the so-called tricot machine or tricot knitting area, or Raschel machine or raschel knitting area. And this is a special machine. This is a raschel machine. Obviously, you can see it how to take up device takes the fabric out of the knitting area. So if it goes directly to the ground or goes 90 degrees under the take up, then it's a so-called raschel machine. And in the raschel machine we have a knitting area with handling on the ground bar the knitting yarn. And our special machine on the technical textile is the so-called weft-insertion machine. We have a second yarn system, which is integrated behind the machine in 90 degree direction to the production direction. So it's perpendicular to the production. And we are using this weft yarns to have aligned fibers and then stitch them together with our second or our first yarn system, which is the warp yarn. So this machine is specifically done for medical applications. It can be used exactly for medical applications. For example, it can handling hollow fibers which can be used for filtration. Not only medical can be used for every filtration application where you have a hollow fiber which, like a hollow fiber membrane inside, goes something outside around the fiber goes something. And you can, for example, enrich with gas or take some other substances out of the liquid. So this is a typical filtration application. So the specific topic on this machine is that we can really handle sensible fibers which have a sensitivity against tension here to hold for example the diameter. You can really handle fibers with a tension below ten centinewton. And then we can really align the fibers. And the warp yarn also helps to hold the fibers on a different specific distance. And then we roll them to a fabric. We have only fibers functional fibers perpendicular to production. So and particularly Raschel is for low modulus fibers. And not particular on this machine here, because it is a specific raschel machine. Now that is something on the knitting area which helps to reduce the tension during the knitting process. Yeah. -Okay. So that's that's good to know that the modulus of the fibers also require different kinds of mechanical processes. -Yeah. Exactly. Because as you I think it's obviously that the understanding if you have high tension on a fiber which has a defined diameter especially have you, if you have a hollow, hollow fiber that you want to go with a fluid flow. So if you have too much tension, you have a elongation on the fiber. And this reduces the diameter. And so you minimize the volume fluid volume which can go through this you want to avoid. So what would be a typical application now. Yeah. As mentioned before it can be used as a hollow fiber in a hollow fiber membrane. Many fibers are rolled and incorporated into a cartridge, which can be done here in such a cartridge. All fibers are aligned, and you can go with a medium through and outside of the fibers alone. -And what is this cartridge for? For dialysis, for the enrichment of blood, for ECMO for example, for. Medical applications. -Medical applications. Medical applications. Okay. Wonderful. All right. So what else can done what is the investment of this machine. Yeah. So the investment depends on the customer needs. Yeah I would say starting point of such a machine is around about 500,000. You can go up to more or less 1 million. Yeah. Okay. So between half a million and one million invest. Right. -Where are you? And I assume 20 years. No problem to. -So this is what Karl Mayer stands for, that if you have a machine, you can run robust. Very robust machines. What is the oldest machine you came across of Karl Mayer? -I would say it comes from the 1990s. 1990? -Yeah. 1990s? 1990s? Yes. Okay, so 30 years old. Okay, good, what else could you suggest to an investor who wants to invest in technical textiles? What would be a cool trend for this machine right now? -Yeah. Okay. How to say we have global trends. Global trends are we have demographic topics. We have older ordering. Um yeah. Society. So medical is always a good investment of course. But also we have these applications in how to say wastewater management for example. Yeah. Filtration can be also for wastewater or for drinking water. So you know we have an increase of of welfare and that we have global growth still in the in the citizens in, in growing countries. And this means you also have their a trend to increasingly support this situation in this application can be also used. We discussed this with some customers. You can really integrate fine metal yarns for some conductive applications. So this is also a topic. Like in the plane I saw in the carbon fiber. Totally different weaving technology of course, but you got the metal inside in order to get the. Contacting or against lightning. -Lightning strikes. Exactly. -Been put away. Yeah. Okay. So there are some trendy markets out there. So dear community, have a look at it. Um, so now we are in the Textile Innovation Center. Why did you decide to put this machine here? Yeah. Since this is especially here on the European market now and and machine. We have requests. Yeah. And um yeah to to put this machine here is to have this, um, shown this development we made for the special development of the knitting head. This is this we have since I would say now one year and there is now the aim to show this machine to the market here because, as you know, you can't go to other customers to show the machine for competitive competitors of this costumer, of course. So and all the machines, normally if a customer buys such a machine is running 24 over seven. Yeah. -In many applications. So we need this showroom here to show new machines, new developments that customers can come, can see what the machine can do, can test some new applications, fibers and so on. So this is why the overall business units need such an application center. and the combination of shown the application. So the world of the customers, of our customers which are the end user. This is also interesting to come in discussion with our customers on new markets, new business models. We can support them. We also have this inspiration hub, which is like a archive of our last 60 years of samples we ever made, which are all there. And you can see what maybe was made already 30 years ago, which forgotten in the society and are this was made some years ago. So this is interesting. -Community since I know Jürgen for quite a few years now, I've met you first time in Chemnitz. I know he's a brain. He's a very good engineer. And I like to challenge you. Are you okay with that? Okay, so the challenge is I'm not from the medical industry. I'm from the filtration industry. Now, explain our community once they come into the Textile Innovation Center. And I want you to show me this for filtration. How would you modify this machine in the Textile Innovation Center to make this demonstration work? Yeah. Money is no problem. Okay. Yeah. This is. This always sounds good. Yeah. If money is no. -Money is no problem. We say money is no problem for this purpose. Yeah. Then we can start really at a single fiber. Because the fiber for the filtration is the functionality. Yeah. So and the fiber can have diameter beginning, let's say 100 micrometers can be up to one two millimeters. Okay. And to handling such different diameters means you have to start a the creel. Right. We have to adapt the creel from the bobbin. Then you have to show how we can insert weft insert yarn in the transport chain. And then we have to talk. What is the volume you want to go through this. What is your filtration productivity. -How do you mean the filtration media. Yes. Okay. -Yeah. Because then we can decide how many single fibers we want to have on a certain volume. Then we can talk about the pressure you want to integrate. What is the membrane material? It's a polypropylene. It can be different materials. And then we have to look how we can handle here inside. Yeah. Because we have a huge variety of, for example, the, the density of yarns per centimeter. We can play with the knitting yarn. What should be the distance between the fibers. This is also what we can adapt. Then we have to talk about should we at a certain frequency integrate another fiber. Because we can handle different fibers in a typical period. The frequency of of one yarn. Then 23rd is a other yarn. And so on. This we can also play with um of course color and normal variable is a topic. I think for this application color is not so. -Could. Be, but could. -Maybe not. Yeah, exactly. And then maybe afterwards want to cut in certain lengths. Then we can discuss what should be the cutting of your your the cutting length of your yarn you want to integrate in the cartridge because the length of the cartridge gives the boundary condition on how many pieces we cut out of our fabric. And then we can also adapt the yarn, the warp yarn density, because we can adapt it to the cutting length of the of the length of your hollow fibers are integrated in the cartridge. So this is a huge field of a playground we can discuss. -So first of all you need a good interaction with your customers. Your customer requirements must be rather clear. Yeah. Or Like the filtration performance you would require, and you would translate this then into a textile product. And once you have this textile product defined, you will go into the machine parameters. And you would start from the bobbin really the creel through the machine and then winding it up to the size so that your output becomes what you require for your filtration cartridge cassette, whatever is possible. So you would be really talking with your customer, the whole chain through from the products performance he's requested to the make of the product. Yeah. So what we also have now in trends in since some years that I mean our customers producing day and night fabrics. Uh, they often have no time to also show left and right what is a trend. So sometimes especially also in the composite market, because then you only have a fabric coming out of our machines. You have many production steps afterwards until the end user. So often we also discuss with our customers the need for their customers, which could be a business case for our customers to understand what could be other. They are what can be done with the fabrics coming out of our machine. You mean your customer sometimes have a blind spot and you help them cover those blind spots because of the big picture you're having on the market? -Exactly, exactly. Smart. Very smart Jürgen. -Yeah, this is a topic you need. Especially this makes you different also, right? Yeah. Especially in the competition to mass markets. Yeah. You see community we are talking here in Obertshausen. This is in Hessen and this is in Germany right. Yeah. So this is a German machine industry in practice. Jürgen. Fantastic. I'm really proud of you. Thank you so much. Thank you for visiting us. -Yeah. I don't know how you would rate this, but this is a ten of ten. consulting from you guys. Yeah. Thank you so much. Thank you. We're happy to have you here. And this is why we have this textile innovation center to show this our world of warp knitting. Yeah, absolutely.