**4.2.3 Production of interlaced 3D fabrics**

The aim of producing a full interlaced 3D woven fabric is to provide a flexible-structure composite which exhibits high mechanical strength against repeatedly exerted loads and, at the same time, enjoys the advantage of light weight. This process is first developed by Fukuta (Fukuta et al., 1982).

In this manufacturing method, X and Y referred as horizontal and vertical weft yarns respectively, are interlaced with the rows and columns of Z multi-layer warp yarns respectively. In this method, shedding of multi-warp Z yarns is not performed only in the fabric thickness direction like in orthogonal 3D fabric formation but it is performed also across the fabric width. To do this, a dual shedding is needed.

In addition to dual shedding that enables column-wise and row-wise sheds to be formed, in order to produce a fully interlaced 3D woven fabric; a grid-like multiple-layer warp (Z), and two orthogonal sets of wefts (X—set of horizontal wefts and Y—set of vertical wefts) are required (Khokar, 2001).

The dual shedding is performed as shown in Figure 29 (a-i). In Figure 29 (a), the grid-like multiple layer warp yarns Z are in their initial position. Multiple synchronized column-wise sheds are formed (Figure 29 (b)) in which vertical wefts Y are to be inserted (Figure 29(c)) and after the insertion of vertical weft yarns Y all the sheds are closed. The produced fabric structure up to now is given in Figure 29 (d) which is a result of interlacement of vertical

one carrier distance; rotation of circumferential yarn carriers by one carrier distance; moving radial yarn carriers between outer and inner edges of the machine bed; beating-up the inserted yarns; and taking-up the woven preform from the weaving zone (Bilisik, 2000 as

Fig. 27. Multiaxial 3D circular woven fabric structure and apparatus (Bilisik, 2000).

The aim of producing a full interlaced 3D woven fabric is to provide a flexible-structure composite which exhibits high mechanical strength against repeatedly exerted loads and, at the same time, enjoys the advantage of light weight. This process is first developed by

In this manufacturing method, X and Y referred as horizontal and vertical weft yarns respectively, are interlaced with the rows and columns of Z multi-layer warp yarns respectively. In this method, shedding of multi-warp Z yarns is not performed only in the fabric thickness direction like in orthogonal 3D fabric formation but it is performed also

In addition to dual shedding that enables column-wise and row-wise sheds to be formed, in order to produce a fully interlaced 3D woven fabric; a grid-like multiple-layer warp (Z), and two orthogonal sets of wefts (X—set of horizontal wefts and Y—set of vertical wefts) are

The dual shedding is performed as shown in Figure 29 (a-i). In Figure 29 (a), the grid-like multiple layer warp yarns Z are in their initial position. Multiple synchronized column-wise sheds are formed (Figure 29 (b)) in which vertical wefts Y are to be inserted (Figure 29(c)) and after the insertion of vertical weft yarns Y all the sheds are closed. The produced fabric structure up to now is given in Figure 29 (d) which is a result of interlacement of vertical

**4.2.3 Production of interlaced 3D fabrics** 

across the fabric width. To do this, a dual shedding is needed.

Fukuta (Fukuta et al., 1982).

required (Khokar, 2001).

cited in Khokar, 2002).

weft yarns Y and grid-like warp yarns Z. Then the warp yarns Z are subjected to form a shed in the row-wise direction (Figure 29 (f)) into which horizontal weft yarns X are to be inserted (Figure 29(g)). The result of interlacing horizontal weft yarns X and grid-like warp yarns Z are shown in Figure 29(h). When the operations of column-wise and row-wise shedding are performed sequentially, and the corresponding wefts are inserted backward and forward in the aforementioned sheddings, the structure of plain-weave 3D fabric is formed that is shown in Figure 29(i).

Fig. 28. Fully interlaced 3D woven fabric structure isometric view (a) and orthogonal view (b) (Fukuta et al., 1982).

However, these fabrics suffer from the crimp and fibre damage problems (Mohamed & Bogdanovich, 2009). As the shedding operation alternately displaces the grid-like arranged warp yarns Z in the thickness and width directions, two mutually perpendicular sets of corresponding vertical wefts Y and horizontal wefts X are inserted into the created sheds. The warps Z, therefore, interlace with the sets of vertical Y and horizontal X wefts, thus creating a fully interlaced 3D woven fabric. Due to the interlacing, the resulting structure has crimped fibres in all three directions, which would be detrimental for potential applications of this type of fabric as a composite reinforcement

Fig. 29. Dual-directional shedding and corresponding picking for weaving fully interlaced 3D fabric (Khokar, 2001).

With the use of 3D weaving, fabrics having different through-thickness properties can be produced. Amounts and types of binder yarns such as carbon, glass, Kevlar and ceramic fibres in through-thickness can be used to tailor the properties of a composite for a specific

Composites produced from 3D woven fabrics have higher delamination resistance, ballistic damage resistance and impact damage tolerance. These aforementioned properties have been a major problem in composites produced with traditional 2D weaving used in military

Today, textile structural composites are widely used in many application fields that usually consist of stacked layers known as 2D laminates, exhibit better in-plane strength and stiffness properties compared to those of metals and ceramics. However, the application of 2D laminates in some critical structures in aircraft and automobiles has also been restricted by their inferior impact damage resistance and low through thickness mechanical properties when compared against the traditional aerospace and automotive materials such as aluminium alloys and steel. In order to improve interlaminar properties of the 2D laminates, three dimensional (3D) textile preforms have been developed by using different manufacturing techniques like weaving, knitting, braiding, and stitching. Among these manufacturing techniques, sewing and 3D weaving are the promising technologies which

In order to comprehend 3D weaving technology and its products, the production techniques

Adanur S. (2001). *Handbook of Weaving*, Technomic, ISBN 1-58716-013-7, Pennsylvania,

Anahara, M., Yasui, Y., Sudoh, M. and Nishitani, M. (1993). *Three Dimensional Fabric with Symmetrically Arranged Warp and Bias Yarn Layers*, Patent No. USP 5 270 094. Badawi S.S. (2007). *Development of the Weaving Machine and 3D Woven Spacer Fabric Structures* 

Behera B.K., Mishra R. (2008). 3-Dimensional Weaving, *Indian Journal of Fibre&Textile* 

Bilisik K. (2011). Multiaxis Three Dimensional (3D) Woven Fabric, In: *Advances in Modern* 

Bilisik K. (2010). Multiaxis 3D Weaving: Comparison of Developed Two Weaving Methods

to the Preform Properties. *Fibers and Polymers*, Vol.11, No.1, pp.104-114

*for Lightweight Composites Materials*, PhD Thesis, Technical University of Dresden,

*Woven Fabrics Technology*, Vassiliadis S., pp.79-106, InTech, Retrieved from: http://www.intechopen.com/books/show/title/advances-in-modern-woven-

Tube-Rapier Weaving versus Tube-Carrier Weaving) and Effects of Bias Yarn Path

application (Mouritz et al., 1999).

**7. Conclusion** 

**8. References** 

USA.

Dresden, Germany.

fabrics-technology

*Research*, Vol.33, pp.274-287.

aircraft structures (Mouritz et al., 1999).

address the shortcomings of the stack-reinforced composites.

and their principles have been reviewed in detail within this chapter.
