Non-Woven, Needle-Punched Fabrics & Felts: Face Structured Textiles
Application examples: Consumer/Recreation
- Felts for garments & crafts
- Column Wrap
- Wall Covering
- Putting Green
- RV Headliner
- Trailer Bunk
- Carpet Tile
- Carpet Underlay
- Patterned Runners
- Loop for Hook & Loop
Application examples: Industrial/Medical
- Walk-off Mats
- Membrane Roof Slip Sheet
- Pond Liner Slip Sheet
- Epoxy Roller
- Filtration, Drainage
- Substrates, Scrims
- Anti-Friction
- Abrasion Prevention
- Cast Wrap
Application examples: Automotive
- Customers: General Motors, Ford, Chrysler, Navistar, Nissan and Hyundai.
- Processes: Flat punch, Velour, DiLour, Die Cut parts & blanks, light assembly & PSA lamination
- Components supplied to: cut & sew, adhesive molding, edge-wrap & Compression molding operations
- Supplies components for the following applications:
- Seat Back & Toe Rail
- Rear Package Tray
- Console
- Door Trim
- Trunk Trim
- Arm Rest
- Head Rest
- Spare Tire Cover
- Lumbar Support
- Seat Frame/Foam Separation
- Load Floor Carpet
- Glove & Utility Tray Liner
Features of Needle-punch, Engineered Fabrics
- OEM Custom Constructions and Colors
- Lightweight
- Sustainable
- Cut-able
- Moldable
- No Binding Required
- Fade Resistant
- Stain and Mildew Resistant
- Will not Fray or Unravel
- Die Cutting Services Available
- Secondary Operations Available
Standard Patterns
Random Velour
Hobnail
Chevron
Fine Single Rib
Standard Dual Rib
Many others
Needle-punch Technology
- Needle-punch, non-woven fabric production involves the binding of fibers through random mechanical interlocking.
- Needle-punching uses barbed needles to interlock the web layers of fibers with the layers around them.
- The density, loft and function of the fabric is controlled by needle density, penetration depth, gauge, barb shape & density, point type and blade shape (pinch blade, star blade, conical) and the fiber and web that they interlock.
- This is a pure mechanical bond; no water, air, heat or chemicals are necessary unless the finished product application requires it.
- The products made by the needle-punch bonding method are 3-dimensional with excellent wear, flexibility, drainage and air permeability characteristics.
Process Technology
- Bales of Fiber: Polyester, Polypropylene, Rayon, Acrylic
- Fiber opening & Mixing
- Fiber Hopper
- Carding
- Cross lapping
- Web Feeding
- Pre-needling (pre-punching)
- Flat Finish Needle-punching
- DiLour Finish Needle-punching
- Calendar & Heat Treating
- Slitting, Edge Trimming & Winding
- Die cutting, laminating & Finishing
Executive Summary
- OEM product lines include Needle-punch flat and 3-D patterned fabrics for Medical, Marine, Roofing, Recreational Vehicle, Wall Covering, Flooring & Matting, Industrial, Construction, Automotive and Consumer applications.
- Focus on continuing to improve its existing Needle-punch technologies and to Engineer solutions that have not previously benefitted from the inherent cost savings and flexibility of Needle-punching.
- As a Solutions Innovator, structured to produce short runs of Needle-punch fabrics in addition to larger volumes typically characteristic of the needs of Automotive, Flooring and Construction OEMs.
Facilities and Capabilities
- warehouse and production facilities totaling 90,000 square feet
- 6+ production lines
- Maximum width up to 180 inches (15 feet)
- Staple fiber lengths from 1.5 to 4.0 inch
- Denier from 3 To 200
- Weights from 180 GSM
- Loft from 2mm Flat punch to 12mm Velour/DiLour
- Loop and Fiber end
- Thermal Bonding, 3-D Patterning, PSA application and Die Cutting
- Fully staffed and equipped, Quality Control facility
Quality Control
- Quality Manual and Procedures
- ISO 9001:2015
- Statistical Trending at each operation
- QC Lab (600 square feet)
- Dedicated QC Personnel
Get In Touch
Contact us to see how we can help meet your technical product requirements!