This document provides an overview of 3D weaving techniques and applications of 3D woven fabrics. It discusses the differences between 2D and 3D weaving, classifications of 3D fabrics, manufacturing processes for 3D weaving including multi-layer and orthogonal weaving, and applications of 3D woven fabrics in composites, medical textiles, transportation and other industries.

1. An Overview of 3D Weaving, weaving technique
with looms & application of 3D woven fabric.
Shariful Islam
M.Sc in Textile ( Fabrics Engineering) , BUTEx
E-Mail: Sharifultex51@yahoo.com
Mobile No: 01725399212
Farid Ul Islam
M.Sc in Textile ( Fabrics Engineering) , BUTEx
E-Mail: faridbutex@gmail.com
Mobile No:01917697606

2. 3D-Weaving
3D-Weaving is a complete new concept in case of
weaving. The first method of 3D woven fabric
denotes 3 Dimensional fabrics, that is length,
width and breadth. In 3 Dimensional fabrics, the
thickness is an important criterion. Ordinary
fabrics also have length, width and breadth, but in
the 3 Dimensional fabrics, the thickness is much
more than ordinary fabric. The thickness is achieved by forming multiplayer using multi series of
warp and multi series of weft, which are intersecting at regular 90o angle as in usual
cloth weaving principle.
It cannot be performed with existing traditional methods and machines. It interlaces a multiple
layer warp with multiple horizontal wefts and multiple vertical wefts producing directly shell,
solid and tubular types of fully interlaced 3D fabrics with countless cross-sectional profiles.
The term 3D weaving is commonly used in reference to the weaving of cloths that have pre-
designed three-dimensional shapes, or can be directly manipulated into a 3D shape immediately
after being woven. It is also used to describe the weaving of fabrics with substantial thicknesses,
many times greater than the diameters of the yarns used to produce the fabrics.
3D woven fabrics play an important role in the development of advanced fibre reinforced
composites. They are used as preformed shapes ready for resin impregnation or as thick
materials with structural integrity, which when resinated have good interlayer shear strength and
thereby outperform conventional laminated products.
First demonstrated in 1997, Dual-Directional (D-D) Shedding System is indispensable for
performing 3D-weaving. This path breaking development has advanced the technology of
weaving to a new dimension.
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3. Difference between 2D and 3D weaving
A traditional 2D weaving process requires two sets of orthogonal yarns, the warp and the weft to
be interlaced and intersected at right angles. On the other hand 3D weaving involves three
orthogonal set of yarns, the warp and weft layers interlaced in thickness direction by binding
warp or weft yarns. Mono-directional shedding process is employed in 2D weaving with single
or multiple layers of warp yarns whereas a thick planar sheet or solid form with dual directional
shedding are used in 3D fabrics.
With the help of 3D weaving, complex net shaped preforms can be produced in order to reduce
the material cost and handling time, which ultimately deliver better mechanical properties. 3D
woven composites posses a higher failure strain than compared to 2D laminates. The post impact
mechanical properties of 3D composites are superior to that of 2D. High ballistic and low
velocity impacts are vital features of 3D woven composites that lead to damage resistance.
Comparison of 2D and 3D fabrics:
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4. 2D Weaving
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5. 3D Weaving:
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6. Classification of 3D fabrics
Woven 3D fabrics can be classified into following two ways:
• Based on Type of Weaving Process
– 2D weaving – 3D fabrics
– 3D weaving – 3D fabrics
– Noobing
• Based on Type of 3D Structures
– 3D Solid—Broadly there are three types of 3D solid structures
–multi-layer
–orthogonal
–angle interlocked
– 3D Hollow
–flat surface
–uneven surface
– 3D Shell
–by weave combination
–by differential take-up
–by moulding
– 3D Nodal
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7. There are various classifications based on the shedding process, weaving mechanisms,
geometrics, and interlacements of the 3D woven architecture. Based on structures 3D fabrics are
divided into four broad types and they are as follows:
1.3D Solids: Solid cross sections in a broad panel or a net shaped perform are woven to form a
3D architecture of these fabrics. Multilayer and orthogonal yarns interlaced together defining the
width and the thickness form the structure of 3D solids.
2.3D Hollows: Multilayered structured with tunnels running in the warp, weft, or in the direction
of the thickness of the structures. 3D hollows can be flat or even surfaces and uneven surfaces
with tunnels on different levels in multiple directions.
3.3D Shells: The shell structures consist of integrated single-walled sections in the direction of
the width and thickness of the fabric forming a cross-sectional shape without a tunnel.
Depending upon the weaving combinations used, the fabric can either be spherical or open box
shells.
4.3D Nodal: The nodal structure comprises of woven tubes joined together. Single walled or
multiple walled sections in the direction of the width and thickness of the fabric can be found
with more than one tunnel openings in the fabric length direction.
Manufacturing Technology of 3D-Weaving
Special looms are required to operate the warp threads in 60o angle for weaving 3Dr-3
Directional fabrics. But the 3 Dimensional -3Dm- fabric can be woven by using ordinary loom
with usual weaving principle-shedding, picking, beating - by having multi layers of warp and
multi layers of weft. Even though the treble cloth with 3 series of warp and weft could be called
3Dm fabrics, in general, minimum 4 series of warp and weft are used in weaving to form several
layers, one above the other to get the sufficient thickness resulting into 3 Dimensional fabric.
As per the principle of weft Tapestry fabric, to weave 3Dm fabrics, it is required to use one
series of stitching warp and multi series of separating warp as per the number of layers to be
formed.
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• As seen from the cross section, the stitching warp passes from top to bottom and bottom
to top but all the separating warp lies almost straight and hence the stitching warp takes
up more length than the separating warp. Therefore, the stitching warp is brought from a
loose tension beam and the entire separating warp is brought from another normal tension
beam.
The following points are to be understood from both the cross sections:
The first layer weft (Face) - shown as "a" - lies between the stitching warp (shown as 1)
and first separating warp series (shown as 3).
The second layer of weft (Middle) - shown as "b"- lies between the first and second
separating warp series
The 3D weaving process is carried out as per following sequence.
 (a)The warp yarns are arranged and supplied in a grid-like arrangement.
 (b) Warps are displaced in the vertical direction to create multiple horizontal sheds.
 (c) Corresponding number of horizontal wefts are inserted into the created sheds.
 (d) The multiple horizontal sheds are then closed, whereby the warp yarns become
interlaced with the horizontal weft yarns.
 (e) The warps are at their level positions in the weaving cycle.
 (f) Next, the warp yarns are displaced in the horizontal direction to create multiple
vertical sheds.
 (g) Corresponding number of vertical wefts are inserted into the created sheds.
 (h) The multiple vertical sheds are then closed, whereby the warp yarns become
interlaced with the vertical weft yarns.
These sequences of operations are repeated once more to insert the wefts in the respective
opposite directions to complete one cycle of the 3D-weaving process to obtain the woven
structure
3D Shape Weaving
Conventional rapier-dobby looms can be used to produce certain three dimensional shapes by
weaving multiple layers of fabric interlinked to each other, similar to a ‘double cloth’, so that
after being woven the layers of 2D fabric can be manipulated into the required 3D shape; for
example, a dobby loom can be used to produce the cellular structures of Fig. 8. For obvious
reasons, this method is also termed multilayer weaving.
Rapier-Jacquard looms are used to produce directly woven thin, complex, 3D-curved geometries,
such as the helmet, the dome and the motorbike body panel shown in Fig. 9. These shaped

9. Page9 of 16
structures are essentially based on 2D weaves, where the weft and warp yarns are in the
horizontal plane, by convention in the x and y directions, of the fabric. No yarn lengths are
present in the z direction of the fabric to give the 3D shape its thickness; the thickness is given
by the diameters of the warp and weft yarns.
3D Fabric Weaving
Although the above shapes may be classed as woven 3D structures, an actual woven 3D fabric is
constructed so that lengths of its constituent yarns are positioned in the z- direction to produce
the fabric-thickness, as well as lengths being arranged in the x- and y- directions for the fabric
length and width. The conventional 2D multilayer weaving can be used to construct 3D fabrics,
but for profiled 3D fabrics (i.e. thick fabrics with a designed shape - termed shaped 3D fabrics)
specially built looms are required.
2D Multilayer Weaving of 3D fabrics
Two techniques are used:- interlacing and non-interlacing
Interlaced 3D Fabrics
With an interlaced 3D fabric, multi-layers of warp and weft yarns provide the fabric thickness (z)
as well as its length (y) and width (x) by the action weft or warp interlock as illustrated in
Fig.10. The multi-layer warp lengths are placed to give the fabric thickness by a pre-set
sequence of the shedding operation across the loom width (or fabric-width) to enable the correct
interlacing with the weft. Notably, the yarn lengths making up the x, y, z directions of such 3D
woven fabrics are not geometrically at 90o to each other (i.e they are not orthogonally
positioned).
Non-interlaced 3D Fabrics
Whereas interlaced 3D-fabric weaving involves only two sets of yarns, a non-interlaced 3D
fabric requires three sets of yarns as depicted in Fig.11; a multilayer warp (z-direction) and weft
(x-direction), and a binder warp (y-direction). As the figure shows, the loom’s shedding
operation requires only one heddle (or heald frame) which is used for the purpose of laying-in
the binder warps in the z-direction to firmly hold the multiple layers of the other yarns thereby
forming the fabric thickness. This process of weaving 3D fabrics is referred to as Noobing, i.e.

10. Non-interlacing, Orientating, Orthogonally and Binding, which are the key features of both
process and fabric.
3D Weaving of 3D Fabrics
As stated above these are specially constructed looms which can produce directly woven
complex shaped 3D fabrics of substantial thickness. The designs of such looms are not publically
available, but certain basic features are described in accessible patents. These patented processes
are referred to as true 3D weaving because the weaving actions enable interlacement of three
orthogonal sets of yarn: a set of multilayer warp (Z) and two sets of weft (X & Y), referred to as
the horizontal and vertical wefts, respectively. Fig 12 illustrates how the three orthogonal sets of
yarns can be interlaced to produce a ‘fully’ interlaced 3D fabric. To achieve this form of
interlacing requires duel-directional shedding of the multi-layer warp (Z); that is to say, a
shedding operation in the fabric-thickness direction as well as in the fabric-width direction,
forming multiple column-wise and row-wise sheds. This ‘duel-directional’shedding occurs
sequentially and not simultaneously. The two orthogonal sets of weft are then alternately
inserted in the mutually perpendicular multiple sheds. Since each weft is interlaced around a
warp yarn, the warp yarns remain straight. As is apparent form Fig.12, any yarn movement is
fully constrained resulting in a highly stabilised fabric structure.
Fig. Multilayer Woven Cellular Structures produced on Conventional Loom
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11. Fig 3D Complex Shapes Woven on Conventional Jacquard Loom
[Source: Innovative Textiltechnik GmbH http://www.shape3.com/Frameset_Shape3.htm]
Fig. Interlaced 3D fabric structures
Fig. Weaving of Non-interlaced 3D Fabric Structure
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12. Fig. 3D Woven Interlaced 3D Structure
The following journal article gives further details and information about 3D fabrics for
composites:
3D fabrics have been used in technical textiles for some time now. They are not just striking
nonwovens but have the potential to change the structure of airplanes, building architectures, and
medical textiles. The most basic way to define three dimensional fabrics is textile materials
which have a third dimension in their thickness layer. These fabrics have a huge part to play in
the advancement of complex fibre reinforced
composites.
According to Behera & Mishra, "3D fabrics are
single fabric systems, the constituent yarns of which
are supposedly disposed in a three mutually
perpendicular plane relationship". The ultimate uses
of 3D fabrics depend on the process used to
manufacture them. 3D woven fabrics can either be
pre-designed three dimensional shapes or can be
manipulated to 3D shape after being woven.
Applications of 3D woven
Different weaving processes decide the areas of applications of 3D woven fabrics. 3D weaving
principle, orthogonal principle, angle interlock principle, and dual direction shedding methods
are mainly the four kinds of forms in which 3D woven fabrics can be produced. Such materials
can be used in making conical and cylindrical structures. 3D woven composites are the fabric of
choice for many machinery manufacturers and technical textile manufacturers.
It used in making intricate shapes for applications as flanges, turbine rotors, and beams. 3D
woven performs are also used as filters and meshed in cutting tools, in making fabrics for
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13. Page13 of 16
ballistic protection, in aquatic and marine infrastructures, in ligaments, vascular prosthetics, and
scaffolds for medical purposes, in high performance sports products like shoe shells, and as
advanced textile composites of rigid yet flexible types. Commercial applications include military
and police helmets, bra cups, car body liners, female body armours, parachutes, sail cloths and in
innovative fashion and clothing.
3D performs were first used in place of expensive high temperature metal alloys in aircrafts in
the early 1970's. After 30 years of continuous research and development in 3D woven fabrics has
led to production of superior counterparts with advanced properties. Using 3D woven composites
lighten the weight and are corrosion free. The time required to manufacture is minimal and
reduces the cost of production. Moreover, since no plying, cutting, and stitching are needed,
minimum machining is required to shape and size them. 3D composites also possess inherent
delamination resistance and provide room for greater design flexibility and versatility. The fact
that if 3D fabrics were used in an aircraft would reduce its weight by 30% proves that these
materials are strong and have a high damage tolerance.
3D textile can be used in array of different products. The above mentioned features of 3D woven
fabrics make it a suitable alternative to metal components in mechanical structures. Today, 3D
woven fabrics are providing new dimensions to textile technology and providing wider
composite applications.
A new method has been developed for the manufacture of bifurcated prosthesis used in medical
applications and they are used to replace the defective blood vessels in patients so as to improve
blood circulation.
The 3D fabrics have recently entered the medical field. Their specific area of application is in the
weaving of vascular prosthesis. Vascular prosthesis are surgically implantable materials. They
are used to replace the defective blood vessels in patients so as to improve blood circulation.
Conventional types of prosthesis were made from air corps parachute cloth, vignon sailcloth, and
other types of clothing materials.
Materials such as nylon, Teflon, orlon, stainless steel, glass, and Dacron polyester fibre have
been found to be highly suitable for the manufacture of prosthesis. These materials were found to
be significantly stable with regard to resistance to degradation, strength, and were not adversely
affected by other factors. Dacron polyester, which has bio-compatibility and high tensile
strength, is being used over a period of time as suture thread or artificial ligaments.

14. Real life Application of 3D fabrics:
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15. Page15 of 16

16. References:
1. Tikp.co.uk
2. http://www.3dweaving.com/en/applications
3. Indian Journal of fiber and Textile research,Vol 33sept 2008,PP.274.287
4. 3D Woven Fabrics, Pelin Gurkan Unal, Nam k Kemal University Department of Textile,
Engineering,Turkey
5. Textile innovation knowledge platform.
6. Development of the Weaving Machine and 3D Woven Space Fabric Structures for
Lightweight Composites Materials,Von der Fakultät Maschinenwesen, der Technischen
Universität Dresden zur, Erlangung des akademischen Grades Doktoringenieur (Dr.-Ing.)
angenommene Dissertation M. Sc. Badawi, Said Sobhey A. M.geb. am 08.03.1970 in
Ägypten
7. COMPARATIVE ANALYSIS OF DIFFERENT 3D WEAVING PROCESSES,
MACHINES AND PRODUCTS, M. H. Mohamed and A. E. Bogdanovich 3TEX, Inc.
109 MacKenanDrive, Cary,NC27511,USA
8. Journal of Fashion Technology & Textile Engineering, KTH Engineering Science,
3D,woven Reinforcement in Composites, FREDRIK STIG, Doctoral Thesis, Stockholm,
Sweden 2012
9. T. Roberts. The Carbon Fibre industry Worldwide 2011-2020. Material Technology
Publications, 2011.
10. Griffiths. Boeing sets pace for composite usage in large civil aircraft. High Performance
Composites, May 2005
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Image Courtesy:
1. Pxleyes.com
2. Tikp.co.uk
3. Google