Weaving: Types, Process Flow, and Objectives
Introduction to Weaving
Weaving is the process of interlacing two sets of yarns, namely the warp (lengthwise) and
weft (crosswise), at right angles to create a fabric. It is one of the oldest textile
manufacturing techniques and is extensively used in apparel, home furnishings, and
technical textiles.
Types of Fabric Construction
Fabric construction methods can be categorized into three main types:
1. Woven Fabrics - Created by weaving warp and weft yarns at right angles.
2. Knitted Fabrics - Made by interlooping yarns to form a continuous fabric structure.
● Knit fabric will stretch and then return to its original state The stretchiness will enable
it to mould to the curves of your body. On the other hand a woven will only stretch if it
has a synthetic fibre like nylon in the weave. A woven will allow you to crease it and
create pleats and folds.
● Knits won’t fray, but wovens do. Therefore, you don’t need to finish (eg overlock) the
raw edges of your knit fabrics.
● To get in and out of woven garments you are usually going to need to insert zips,
buttons or some kind of closure. Knits will allow you to stretch the neck or waist to
pull them on.
3. Nonwoven Fabrics - Manufactured by bonding fibers together through chemical,
mechanical, or thermal means without using yarns.
Formation Methods:
● Chemical Bonding: Adhesives glue fibers together.
● Mechanical Bonding: Achieved through needling, fluid jet entanglement, or sewing.
● Thermal Bonding: Heat melts a binder (powder, paste, polymer melt) onto the web.
● Plastics/Pleather/Vinyl: Made from polymer solutions shaped into sheets/films,
used alone or with backings.
Type Process Key Features Examples/Uses
Wet-Laid Fibers in slurry laid on Paper-like texture, Felt, filtration, wipes.
mesh, then bonded. uniform structure.
Spun-Laid Polymer filaments Strong, durable, Interfacing, medical
(Spunbond) spun, cooled, and lightweight. textiles.
bonded.
Stitch Bond Web held with Soft, flat texture. Batting scrim,
chain-stitch seams. upholstery.
Solvent Bond Fibers softened using Controlled bonding Specialty industrial
solvents for bonding. strength. applications.
Thermal Bond Thermoplastic fibers Soft, flexible, Hygiene products,
bonded via heat. breathable. insulation.
Chemical Bond Binders (resin/latex) Soft, resilient, Disposable wipes,
applied to web. strong. medical fabrics.
Hydroentangled High-pressure water Soft, absorbent, Wet wipes, medical
(Spunlace) jets bond fibers. strong. dressings.
Carded Nonwoven Fibers are combed into High durability, Durable textiles,
a web for strength. aligned fibers. filtration.
Applications of Each Type
● Woven Fabrics: Used in garments (shirts, jeans), upholstery, and industrial textiles.
● Knitted Fabrics: Used in t-shirts, sportswear, socks, and medical textiles.
● Nonwoven Fabrics: Used in medical masks, wipes, geotextiles, and disposable
hygiene products.(Find More)
Process Flow and Objectives in Weaving
The weaving process consists of several preparatory steps before actual fabric production.
These steps ensure efficiency, fabric quality, and loom productivity.
1. Winding
● Objective: To transfer yarn from large cones or hanks to smaller packages (bobbins,
cones, or pirns) suitable for weaving.
● Process: Eliminates yarn defects, strengthens weak areas, and ensures smooth
unwinding.
2. Warping
● Objective: To arrange multiple warp yarns in parallel and wind them onto a beam.
● Process: Thousands of individual yarns are drawn from cones, aligned in a precise
sequence, and wound onto a warping beam.
Warping Process In Textile || Direct Warping and Sectional Warping
3. Sizing
● Objective: To apply a protective coating to the warp yarns to enhance their strength
and abrasion resistance.
● Process: A starch-based or synthetic solution is applied to prevent breakage during
weaving
What is Sizing Process in Textile, Sizing Process in Weaving
.
4. Drawing-In and Gaiting
● Drawing-In: Each warp yarn is drawn through the heddles and reed, ensuring proper
alignment.
● Gaiting: The process of setting up the loom by attaching the warp beam and
adjusting the tension.
Drawing in Process in Textile, Denting Process In Textile, Denting Process In Weaving
Types of Weaving
❖ Weaving is classified into shuttle weaving and shuttle-less weaving, each with
distinct mechanisms and efficiency levels.
Shuttle Weaving
Shuttle looms use a traditional shuttle to carry the weft yarn through the warp shed. The key
motions in shuttle weaving are:
Primary Motions (Essential for fabric formation)
1. Shedding: Lifting and lowering warp yarns to create an opening (shed) for the weft
insertion.
2. Picking: Inserting the weft yarn across the shed.
3. Beating-Up: Pushing the inserted weft yarn to the fell of the cloth using a reed.
Secondary Motions (Enhancing efficiency)
1. Warp Let-Off: Releasing warp yarns from the beam at a controlled rate.
2. Cloth Take-Up: Rolling the woven fabric onto the take-up roller.
Auxiliary Motions (Improving quality and automation)
1. Weft Stop Motion: Stops the loom if a weft yarn break occurs.
2. Warp Stop Motion: Stops the loom if a warp yarn breaks.
3. Selvage Formation: Ensures neat fabric edges.
Primary, Secondary, and Tertiary Motion of Weaving Loom
Shuttleless Weaving
Modern weaving technologies eliminate the traditional shuttle and use alternative methods
for weft insertion, improving speed and reducing noise. Major shuttleless weaving methods
include:
1. Projectile Weaving
● Uses small projectile shuttles to carry the weft across the shed.
● Suitable for heavy fabrics like denim and industrial textiles.
● Provides high-quality fabric edges.
2. Rapier Weaving
● Utilizes flexible or rigid rapiers to grip and transfer the weft across the loom.
● Suitable for a wide variety of fabrics, including patterned and multi-color textiles.
● Offers high-speed operation.
3. Air-Jet Weaving
● Uses compressed air to propel the weft yarn through the shed.
● Ideal for lightweight to medium-weight fabrics like polyester and cotton blends.
● High-speed production with minimal mechanical wear.
4. Water-Jet Weaving
● Employs a high-pressure water jet to insert the weft.
● Best for synthetic yarns (e.g., polyester) due to their water resistance.
● Faster than air-jet weaving but limited to hydrophobic fibers.
5. Multiphase Weaving
● Uses multiple sheds to insert multiple weft yarns simultaneously.
● Achieves ultra-high production speeds and maximum efficiency.
● Mainly used for large-scale industrial applications.
Conclusion
Weaving is a critical textile manufacturing process with various types, technologies, and
preparatory steps. The choice of weaving method depends on fabric type, production speed,
and cost efficiency. Modern shuttle-less weaving techniques have revolutionized fabric
production, offering high-speed, low-cost solutions while maintaining quality and versatility.
Understanding the weaving process and its technological advancements helps in selecting
the right machinery and production techniques for specific textile applications.
