What is fabric construction?
Fabric Construction involves the conversion of yarns, and sometimes fibres, into a fabric having characteristics determined by the materials and methods employed. Most fabrics are presently produced by some method of interlacing, such as weaving or knitting.
Yarn Count
Yarn count shows a diameter of yarn which composes a woven in warp or weft. This parameter directly affects density, strength, comfort, and other quality of the fabric. That is because in permanent use even woven with tightly packed thin threads will not work longer than others with more quality material. But this parameter is not enough for understanding quality if the yarn was additionally processed or full fabric has some special finishing. So it is really important to look at the whole list of characteristics of the fabric before making a choice.
Thread Number
The number of threads in an inch of warp or weft indicates how tightly the threads are in the fabric. Together with Yarn County, this parameter describes the quality of the fabric quite fully. If good threads are tightly packed, the fabric will be durable. But at the same time, if the threads are too tight and the fabric is in constant motion and friction, then it can work the other way around. The friction of the threads with each other will cause more damage to the material than contact with other surfaces. In such cases, a special Finishing can help. Additional properties from processing can neutralize unwanted tissue changes.
Weaving
Weaving is a method of textile production in which two distinct sets of yarns or threads are interlaced at right angles to form a fabric or cloth. The longitudinal threads are called the warp and the lateral threads are the weft, woof, or filling. (Weft is an old English word meaning "that which is woven"; compare leave and left.) The method in which these threads are interwoven affects the characteristics of the cloth. The cloth is usually woven on a loom, a device that holds the warp threads in place while filling threads are woven through them. A fabric band which meets this definition of cloth (warp threads with a weft thread winding between) can also be made using other methods, including tablet weaving, backstrap loom, or other techniques without looms.
The most common weaves are Plain weave 1x1 (2x2), Twill weave 2x1, Satin weaves 4x1 but there are also more complex designs. It happens that complex weaving cannot be described by formula and it does not have its own name. Then you need to apply a rapport to the fabric to describe its structure.
Warp and Weft Composition:
Warp and weft yarns of woven fabric could consist of different compositions. For that case, you have the possibility to provide a detailed composition for each of them. You can choose compositions only from points selected in the main composition to make clear how the material is distributed in the product.
Yarn Type:
Yarns can be described as single, or one-ply; ply, plied, or folded; or as cord, including cable and hawser types.
Single, or one-ply, yarns are single strands composed of fibers held together by at least a small amount of twist; or of filaments grouped together either with or without twist; or of narrow strips of material; or of single synthetic filaments extruded insufficient thickness for use alone as yarn (monofilaments). Single yarns of the spun type, composed of many short fibers, require a twist to hold them together and may be made with either S-twist or Z-twist. Single yarns are used to make the greatest variety of fabrics.
Ply, plied, or folded, yarns are composed of two or more single yarns twisted together. Two-ply yarn, for example, is composed of two single strands; three-ply yarn is composed of three single strands. In making ply yarns from spun strands, the individual strands are usually each twisted in one direction and are then combined and twisted in the opposite direction. When both the single strands and the final ply yarns are twisted in the same direction, the fiber is firmer, producing harder texture and reducing flexibility. Ply yarns provide strength for heavy industrial fabrics and are also used for delicate-looking sheer fabrics.
Cord yarns are produced by twisting ply yarns together, with the final twist usually applied in the opposite direction of the ply twist. Cable cords may follow an SZS form, with S-twisted singles made into Z-twisted plies that are then combined with an S-twist, or may follow a ZSZ form. Hawser cord may follow an SSZ or a ZZS pattern. Cord yarns may be used as rope or twine, may be made into very heavy industrial fabrics, or may be composed of extremely fine fibers that are made up into sheer dress fabrics.
Novelty yarns include a wide variety of yarns made with such special effects as slubs, produced by intentionally including small lumps in the yarn structure, and synthetic yarns with varying thickness introduced during production. Natural fibers, including some linens, wools to be woven into tweed, and the uneven filaments of some types of silk cloth are allowed to retain their normal irregularities, producing the characteristic uneven surface of the finished fabric. Synthetic fibers, which can be modified during production, are especially adaptable for special effects such as crimping and texturizing.
Texturizing processes were originally applied to synthetic fibers to reduce such characteristics as transparency, slipperiness, and the possibility of pilling (formation of small fiber tangles on a fabric surface). Texturizing processes make yarns more opaque, improve appearance and texture, and increase warmth and absorbency. Textured yarns are synthetic continuous filaments, modified to impart special texture and appearance. In the production of abraded yarns, the surfaces are roughened or cut at various intervals and given an added twist, producing a hairy effect.
Bulking creates air spaces in the yarns, imparting absorbency, and improving ventilation. Bulk is frequently introduced by crimping, imparting waviness similar to the natural crimp of wool fiber; by curling, producing curls or loops at various intervals; or by coiling, imparting stretch. Such changes are usually set by heat application, although chemical treatments are sometimes employed. In the early 1970s, bulky yarns were most frequently produced by the “false twist” method, a continuous process in which the filament yarn is twisted and set and then untwisted and heated again to either stabilize or destroy the twist. The “stuffing box” method is often applied to nylon, a process in which the filament yarn is compressed in a heated tube, imparting a zigzag crimp, then slowly withdrawn. In the knit-de-knit process, a synthetic yarn is knitted, heat is applied to set the loops formed by knitting, and the yarn is then unraveled and lightly twisted, thus producing the desired texture in the completed fabric.
Bulk may be introduced chemically by combining filaments of both high and low shrinkage potential in the same yarn, then subjecting the yarn to washing or steaming, causing the high shrinkage filaments to react, producing a bulked yarn without stretch. A yarn may be air bulked by enclosing it in a chamber where it is subjected to a high-pressure jet of air, blowing the individual filaments into random loops that separate, increasing the bulk of the material.
Dyed Warp Weft Yarns:
In some cases, warp and weft threads are dyed in different colors. Because of this, it looks like a fabric with a pattern up close, but in the distance it looks like a mixed color. You can provide both warp and weft colors.
Complex Weave
In case if your fabric has more complicated construction and it couldn’t be described in form below you can write as simple as it could be in this field.