Manufacturing Level Equipment for Rapid Prototyping

The suite of manufacturing tools available at the Pennsylvania Fabric Discovery Center (PA FDC) at the Center for Functional Fabrics (CFF) offer full scale industrial production potential. Our manufacturing floor includes state-of-the-art weft knitting, sample warp knitting, sample weaving, fabric embroidery and yarn assembly equipment. There are additional rooms for testing, yarn storage, assembly, dye and finishing. The PA FDC @ CFF utilizes this equipment to push the current boundaries of functional fabrics, smart garments, novel materials, and wearable technology. The ability to explore technologies via our end-to-end rapid prototyping facility allow for direct translation to high MRL production of new technologies.

Flat Weft Knitting

Six industrial flatbed weft knitting machines (gauges between 8 and 15; Shima Seiki SSG122SV, SWG041N, MACH2X, SWG091N2, Mach2XS, SVR123SP) with accompanying state-of-the-art programming, modeling, and design system computers (6 SDS-ONE APEX workstations). All machines provide seamless knitting capabilities, and two machines provide Wholegarment™ capabilities. Traditional plating and iPlating capabilities also available.

Circular Weft Knitting

Circular weft knitting machines with coarse and fine gauges for medium to large garments (Santoni SM8-EVO4J) and shoe uppers (Lonati DC88-2C).

Sample Weaving (CCI Tech Inc.)

A fully automatic sample weaving loom (The Studio), flexible warping machine for preparing beams (Mini Lutan Single-End Warping Machine), and sizing machine suitable for experimental batch sizes (SS600 Single-End Sizing Machine). Warping machine also produces suitable beams for warp knitting equipment. Sizing machine may be used for yarn preparation for a variety of machines.

Sample Warp Knitting

Comez DNB/EL-32 warp knitting machine with electronic double needle bed warp knitting machine to produce a wide range of articles applicable to technical uses, medical uses, and footwear, with yarn/fiber lay-in capabilities.

Embroidery

ZSK JGVA 3-Head Technical Textile Embroidery Machine allowing for incorporation of technical yarn materials such as conductive threads, as well as larger components such as silicone tubing, carbon fiber tows, etc. Capable of generating high surface area stitching and automated placement of small electronics such as RFID or LED. Helps derisk prototype development through proof-of-concept validation.

Yarn Management, Assembly, & Braiding

Hybrid, multi-function equipment for yarn twisting, yarn covering, yarn blending (Agteks DirecTwist 2C6D6, DirectCover 2S, Simet Twisting Machine) and braiding (2 16-spool New England Butt Company Braiding machines). Sample Twister was created at PA FDC to provide a modular twisting set-up for fragile or short lengths of novel materials. Yarn processing accessories to adjust and control angle, rate and directionality of yarn feeding into textile production machinery (creels, yarn accumulators, servo feeders, LGL Spin Feeders and Compact Feeders).

Testing

A variety of equipment suited for advanced analysis of fibers, yarns, and textiles, through optical imaging and physical characterization of mechanical properties, assembly characteristics, and performance characteristics. Equipment at PA FDC includes, but is not limited to, Keyence VHX-950F stereoscopic microscope, Electronic Twist Tester, Yarn Count Tester, Yarn Wrap Reel, Shimadzu AGS-X Universal Tester, Pfaff Seam Testing Station, SDL Atlas Martindale Abrasion and Piling Tester.

General Prototyping Tools

3D body scanner for generation of accurate body measurements (SizeStream SS20 3D Body Scanner), 3D printers, laser cutter, and a variety of state-of-the-art textile assembly and finishing tools for constructing garments and other product prototypes including, but not limited to, Pfaff 8301 Ultrasonic Welding/Sewing Machine, 8303i Hot Air Seam Sealing Machine, Juki Lockstitch Machine, Juki Coverstitch Machine, Merrow MB-4DFO 2.0, Wascomat Washer and Dryer, Reliable Steam Iron, Commercial Vacuum Ironing Board, Powersonic Benchtop Ultrasonic Cleaner.