Development of nonwoven materials

Nonwovens are versatile and cost-effective materials. We are used to seeing nonwovens in car interiors, surface materials in hygiene products, and in molded furniture, but they are often hidden, such as in sound absorbers in dishwashers, dust covers under box springs, and padding in clothing.

Carding

Carding is a process in which staple fibers are separated and blended. By combing the fibers over rollers covered with fine spikes, irregularities are removed. The fibers are evenly distributed into a fiber web that serves as a base material for various nonwoven products. The carding process helps create a strong and uniform structure for further processing.

We offer carding on a pilot scale for all types of natural and synthetic fibers.

Fiber web area: approximately 1 m²
Basis weight: 50-1000 gsm
Fiber length: Up to 150 mm

Needle Punching

Needle punching is a mechanical process used to consolidate fiber webs. Needles repeatedly penetrate through the web, hooking the fibers and moving them up and down, causing them to interlock. This creates a strong and stable material, which can vary in density and strength depending on the application. Needle punching is especially suitable for longer staple fibers and higher basis weights.

Our equipment offers the following capabilities:

Width: 55 cm
Basis weight: 100-500 gsm
Speed, needle density, and needle depth can be adjusted

Thermal Bonding

Thermal bonding is a method where fibers are fused together using heat rather than mechanical processing or chemicals. This process utilizes thermoplastic fibers, which melt when exposed to heat and then bond as the material cools. In our labs, samples can be thermally bonded in batches of varying sizes.

What we offer

RISE can assist in the development and production of nonwovens using the techniques mentioned above.

We can analyze nonwovens through a variety of methods, including several developed by the European trade organization EDANA. We are capable of performing chemical analyses and evaluating materials using microscopy.

We offer tailored and flexible solutions adapted to meet the specific needs of our clients.