T EC H NI CA L T EX T I LESTHE INNOVATIVEMARKET LEADER INTECHNICAL TEXTILES
Automotive / Building and Construction / Transport andAerospace / Renewable Energy / Sports Equipment /Personal Protection / A­ dvertising / Medical Technology /Infrastructure / Apparel and Home Textiles / Reinforce­
ment and Coating Substrates

KARL MAYER TECHNICAL TEXTILES

2 / 18  TECHNICAL TEXTILES
THE INNOVATIVE MARKET LEADER

18 / 3TECHNICAL TEXTILES KARL MAYER

CREATING ADDED VALUE FOR OUR CUSTOMERSTechnical textiles are opening up new end uses; they are replacing conven­tional materials and are used as reinforcing materials in composites for a wide
range of applications, including the mobility, energy, construction and leisuresectors. In the technical textiles sector, KARL MAYER has consolidated its
expertise in machines for producing technical textiles, so that it can cater
optimally for the current and future needs of its clients.
With our innovative machine portfolio, we are the go-to partner for the­industry. We are the drivers of technology and innovation in composites andlightweight construction technology. New materials, such as fibre-reinforced
plastics containing carbon and glass, are a few of the important future tech­
nologies for the automotive and aerospace industries. We are also making animportant contribution to future challenges like saving energy and resources.
There we can benefit from our many years of experience working with ourpartners, for example in the wind turbine sector and in the increasingly impor­tant construction industry.
We also concentrate on efficient production in conventional applications,such as advertising banners and other coating substrates, as well as geo­
textiles, such as in road building.
By working closely with our customers, our aim is to develop systems
that offer the best cost–benefit ratio. We do this by using our sophisticatedstandard platforms as the basis for developing customised solutions.
In this way, we are supporting our customers by developing unique selling
points in their markets and helping them to become the technology leaders.
This brochure aims to show what added value KARL MAYER’s systems canbring to the various applications of technical textiles.
We would be pleased to help you to achieve your goals and are looking­forward to meeting you in person!

KARL MAYER TECHNICAL TEXTILES

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DRIVING INNOVATIONSFORWARDLEADER IN PRODUCTIVITY

DIGITIZING BUSINESS WITH KM.ON

With the latest generation of raschel machines with parallelweft-insertion the fabric output has increased up to 30%.
For example, the maximum speed to produce plaster gridswith the WEFTTRONIC® II G 245" has been increased from1,200 rpm to 1,600 rpm.

Digitisation is a basic component of our company strategy.
With our corporate start-up, KM.ON, we have a software
company at our disposal that can act quickly and customer-­oriented on the market.
We are developing innovative software products and modern,digital solutions and services for our customers so they
can achieve even greater success. We offer eight productcategories, which can be used according to the individual
customer’s needs.

AUTOMATION, INTUITIVE OPERATIONEASY ORDER OF ORIGINAL SPARE PARTS

KAMCOS® 2 (KARL MAYER COMMAND SYSTEM) is ouroperator interface for configuring, monitoring and adjusting
the electronic functions of the machine. Furthermore available
is the KARL MAYER CONNECT app for an easy and intuitive
user assistance. Third-party software can also be accessed
via multiple interfaces.

Virtual order, real benefit – easy ordering of selected spareparts with just one mouse click. KARL MAYER’s B2B platform
WEBSHOP SPARE PARTS ensures a quick and easy access towear and tear parts and to standard spare parts.
Original spare parts guarantee safe machine operation.

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NEW TECHNOLOGY FOR COST-­
EFFECTIVE FIBRE PROCESSING
SIM.PLY combines a completely revised spreading modulewith tailored impregnation technology in a continuous,­efficient processing sequence. The seamless interface­guarantees a consistently high spreading quality.

NEW APPLICATIONSIn the constantly evolving field of production technologies
for manufacturing fibre-reinforced plastics, KARL MAYER
is making a significant contribution to the ­individual process­ing of high-performance fibres.
By combining different materials in various configurations,complex semi-finished products can be produced, whichmakes the best use of the performance potential of the fibres.

TECHNICAL TEXTILES KARL MAYER

SUSTAINABILITY
With its machine portfolio, KARL MAYER can provide theglobal market with sustainable machine solutions. The
fabrics that can be produced provide the potential for­sustainability. Processing high-performance fibres, such ascarbon and glass, and the associated savings that can bemade, for example in concrete as a raw material in the con­struction industry, and in energy in the automotive industry,
are just two promising applications.

OPTIMISING THE PRODUCTION­PROCESSES
On the basis of our industry-proven standard components, we
at KARL MAYER develop solutions for individual machines inorder to guarantee that our customers’ ideas and products will
be successful. By cooperating closely with them, we candevelop new, optimised technologies to guarantee efficient
production processes.

KARL MAYER TECHNICAL TEXTILES

6 / 18  APPLICATIONSKARL MAYER can offer you added
value for every application:• Maximum productivity• High, reproducible quality
through automatic processcontrol• High level of flexibility by
combining a wide range ofdifferent materials• Customised design of theend product• High machine availability,
through its product-­
supporting service­organisation

AUTOMOTIVEYOUR BENEFIT –OUR SOLUTION• Efficient energy consumption
through lightweight constructions• Passenger protection through theselective use of high-performance
fibres (crash safety)• Corrosion resistance throughhigh-performance fibres withsuitable matrix systems

The automotive industry is a producer of highly sophisticated prod­
ucts. For some time now, engineers have been focusing on using
carbon and other high-performance materials based on textiles.
In the future, car chassis and bodies made from high-performance
fibres will no longer be a rarity. The increasing use of lightweightcomponents reinforced with textiles in a car is offering huge oppor­
tunities. In the automotive industry especially, criteria such as low
weight, high stability and customised rigidity are playing a decisiverole. KARL MAYER’s technology can help you to achieve theseambitious goals.

END USES• Structural body components• Exterior• Interior (including blinds)

18 / 7TECHNICAL TEXTILES KARL MAYER

BUILDING AND CONSTRUCTIONYOUR BENEFIT –OUR SOLUTION• High-performance fibres prevent
corrosion and increase the servicelife• A thinner concrete coveringconserves resources and energy• More varied design possibilities
since the materials are freely
formable• Repair work can be carried out
faster for a lower overall cost

The vision for the future of the construction industry is: building lighter,more efficiently and more intelligently, and to think and act in a way thatwill conserve resources. On the one hand, it is a question of efficiency –using lighter building materials conserves resources. On the other hand,the aesthetics are important for creating concrete structures with finerand more varied shapes and forms for the same strength and rigidity.
Repairing and restoring existing buildings and bridges is another areaof the construction industry that is gaining importance. In conventional
applications, such as textile roofs, the textiles produced on our­machines can deliver attractive use and design possibilities.

END USES• Plaster grids• Roofing materials• Textile-reinforced concrete• Pipe repair• Repair and restoration of­buildings and bridges• Building protection

TRANSPORT AND AEROSPACEYOUR BENEFIT –OUR SOLUTION• Efficient energy consumption
through lightweight constructions• Corrosion prevention reduces
maintenance costs• Thermal insulation and fire
­protection• Higher tear propagation resistance,
tensile strength and higher­temperature stability• Possibility of integrating sensors

The aviation industry is the best example of the successful use ofcarbon fibres. Manufacturers are increasingly using components
containing high-performance fibres to replace aluminium compo­
nents in their latest models. This decreases the weight considerably
and reduces the costs of fuel and maintenance.
In commercial vehicles especially, high demands are placed on the
toughness, loading capacity and durability of the materials used.

END USES• Aircraft construction• Commercial vehicles• Boat-building and shipbuilding• Public transport• Lorry and truck tarpaulins• Securing loads

18 / 8TECHNICAL TEXTILES KARL MAYER

RENEWABLE ENERGYYOUR BENEFIT –OUR SOLUTION• Lightweight constructions improve
efficiency and simplify transport ininaccessible areas• Reduced maintenance costs• Possibility of designing optimised
blade geometries

On the wind turbine market in particular, composite structures are
essential for the development of lighter, longer rotor blades with abetter performance. This enables coastal regions and areas whereis less wind to be exploited, further reducing costs. The experience
gained here can also be transferred to other areas where light­
weight construction technology can reduce the weight for the same
performance spectrum.

END USES• Wind turbines• Oil rigs

SPORTS EQUIPMENTYOUR BENEFIT –OUR SOLUTION• Lightweight constructions improve
the performance spectrum• Design freedom, increased custom­isation• Small- and large-scale production,
thanks to flexible machines• Prestige associated with using
carbonHigher, further, faster. The sports industry needs strong yet light­
weight textiles. Customised material compositions using high-techfibres guarantee high strength for low weight.

END USES• Sports and recreational­equipment• Bicycles• Helmets• Motorbikes

KARL MAYER TECHNICAL TEXTILES

9 / 18  PERSONAL PROTECTIONYOUR BENEFIT –OUR SOLUTION• Optimisation of the manufacturing
processes through the production ofmultilayered, warp-knitted textiles• Increased tear propagation resist­ance and abrasion resistancethrough specific textile construc­tions• Combination of different materials
in one production step
• Improved comfort through the use offlexible, high-performance fibres

A wide variety of protective clothing is used in many areas. For
example in this sector KARL MAYER offers technologies for­producing multilayered, multiaxial textiles from aramid fibres forbulletproof vests, as well as machines for producing biaxial, weft-­
inserted, warp knitted textiles from high-performance yarns witha large number of filaments.

END USES• Trousers, gloves, etc.
• Ballistic and antistab vests• Hard ballistics• Car components

ADVERTISING
YOUR BENEFIT –OUR SOLUTION• Maximum productivity throughhigh fabric output, thanks to thewide working width• Broad spectrum of uses throughhigh machine flexibility• Choice of different working widths,
adapted to suit the subsequent
processing stages

Textiles for use in the advertising sector have been especiallydeveloped to be lightweight and transparent, yet strong. They
should ensure that the advertising message is as visible as possible
and they should be efficient and economical to produce – because
their use is frequently temporary and location-specific. This type of
warp knitted textile can be used as the print carrier for example foroutdoor and indoor advertising, for decorating stands at exhibitions
and in the construction industry as privacy screens.

END USES• Billboards• Frontlit• Backlit• Blockout• MeshKARL MAYER TECHNICAL TEXTILES

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MEDICAL TECHNOLOGYYOUR BENEFIT –OUR SOLUTION• Precise handling of delicate fibres• Small-scale production, thanks toflexible machines• Design freedom for individual
customisation• Efficient use of machines throughspecial customer solutions (cut-tolength weft-insertion)

The medical sector has high demands on the quality of the textile
materials used in its field.
Innovative materials with specific stress/strain characteristics areused here, as well as hollow fibres for blood filtration. Carbon offers
particular advantages here. For example, a prosthesis is very flexible
and adapts easily to the body’s movements. It is also stable and cancope with high demands and high levels of stress.

END USES• Prostheses• Blood filtration• Instrument engineering• Mobility

INFRASTRUCTURE
YOUR BENEFIT –OUR SOLUTION• Conservation of resources throughincreased service life of the end
product• Processing of high-performance
fibres and exploiting their maximum
strength levels• Optimum processability, even inadverse conditions of use• Combination of several require­ments by joining different textiles togrid structures

Requirements such as separation, filtration, drainage, reinforcement,
tension equalisation and protection are becoming increasingly
important in the construction industry. Warp knitted geogrids or
geocomposites can be used here. The requirements for the physicalcharacteristics of the textile substrates demand top-quality­production methods in order to optimally exploit the properties of thehigh-­performance fibres.

END USES• Mining• Bank and slope reinforcement• Road and railway building• Landfill and tunnel construction• Reclamation of opencast mines• Drainage

18 / 11TECHNICAL TEXTILES KARL MAYER

APPAREL AND HOME TEXTILESYOUR BENEFIT –OUR SOLUTION• Maximum productivity through highfabric output, thanks to the wide
working width• Production of the finest, warp
knitted textile constructions fromdelicate fibre materials• Wide variety of patterns, thanks to
the flexibility of the machinetechnology

We can supply machines for producing for example knitted inter­
linings for the clothing industry. Depending on the area of applica­tion, these can be used to permanently retain the shape of thegarment, prevent creasing and improve function. Home textiles arecharacterised by their individuality, wide variety of designs, theircolours and the types of materials used. Our machine concepts
enable us to offer you the best solution for your particular require­ments.

END USES• Interlinings• Protective clothing• Bedding• Upholstery fabrics• Blinds and privacy screens• Outerwear

REINFORCEMENT AND COATING SUBSTRATESYOUR BENEFIT –OUR SOLUTION• Maximum productivity through highfabric output, thanks to the wide
working width• Broad range of applications throughmodular machine technology• Wide variety of fabric constructions,due to the production of­product-specific openings

All sorts of warp knitted coating substrates, which are usually madefrom high-strength polyester yarns, feature two straight yarn layers
in the 0° and 90° directions. They are fixed with the knitting yarn toproduce a textile substrate with a particularly high tear propagation
resistance and exceptional tensile strength values for low weights
per unit area.

END USES• Swimming pools• Sun screens• Trade fairs• Adhesive tapes• Tarpaulins

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KARL MAYER AS A DRIVER OF CUSTHUESKER GROUP©HUESKER GroupThe HUESKER Group based in Gescher, develops and manufactures
geosynthetics and technical textiles, which are used in tailor-madesolutions for the construction, agricultural and industrial sectors.
The enterprise was set up in 1861, it operates internationally, andhas roughly 540 employees. HUESKER’s key to success is linked tothe company’s first-class engineering performance and production
technologies, many years of experience in the fabric production,
coating and making-up of technical textiles, as well as its innovative
strength.

“We have been working together with KARL MAYER for morethan 30 years, our cooperation being characterized by mutual
trust and successful outcomes. Our geotextiles and technicaltextiles for agriculture and industry have always met thehighest demands in terms of quality, reliability and safety, on
which our customers can rely 100%. There are no limits forour ideas. It is important to have the right partner for every­situation.”Heinz-Georg Richels, Vice President Manufacturing HUESKERGroup
KARL MAYER delivers warp knitting machines with course-oriented
weft-insertion for the production of geo-grids to HUESKER. Bymeans of these models it is possible to efficiently produce gridswith different mesh openings made from various technical yarns. A
special technical equipment for HUESKER enables the manufactureof especially stable, heavy grid variants.

RELX
Reliance Composite Solutions, RelX, is the composite brand of theinfluential conglomerate Reliance Industries Ltd. with its head officein Mumbai. This global player was founded in 1966, and today it is
the largest and most profitable private enterprise in India. Besides,
it belongs to the world’s biggest companies of the „Fortune Global
500“ list.
RelX supplies composites with a great variety of designs and­excellent quality. The highly innovative composite solutions enableapplications in the most diverse areas, among other things in­renewable energy.
“The machines are utilized for competently producing Glass
Fibre Fabrics which are a vital part of Technical Textiles which
suffice the requirement of FRP/CFRP composites products.
We have been dealing with KARL MAYER since long and we areglad to use their machines and each part of machinery whichenabled us to perform in each of business and management
aspects.”
Rajesh Patel, Plant Manager – Technical Fabrics, Reliance
Composites Solutions

For producing its technical textiles, RelX uses KARL MAYER’s
multiaxial and biaxial warp knitting machines. These machines
impress with the high quality of their products and their flexibility.

18 / 13TECHNICAL TEXTILES KARL MAYEROMER BENEFITSYOUSUNG INDUSTRIAL FABRICSYOUSUNG Industrial Fabrics produces high-quality technical­textiles, which are mainly used for making coating substrates. The
enterprise was founded in 1960. The warp knitting division for thefield of technical textiles was set up in 1999, with machines suppliedby KARL MAYER. Their output amounts to up to 2.4 million runningmeters of weft-insertion warp knitted fabrics per month.
For ensuring the company‘s success, YOUSUNG Industrial Fabrics
relies on a close partnership with its customers. With its know-how
and technical possibilities, the manufacturer develops solutions
offering highest customer benefit.
“KARL MAYER produces incomparable machines. By means of
the offered technical possibilities, we are in a position to provide
our customers with solutions which enable them to be always
one step ahead of the competition. Moreover, KARL MAYER is areliable partner whom we can fully trust.”
Mr. Oh, President of YOUSUNG Industrial Fabrics

OUR KNOW-HOW IS
YOUR STRENGTH• Realisation of end-use-oriented technical solutions suppor­
ted by the expertise of recognised experts in processing
technology• Tailor-made, customer-specific, complete solutions basedon industry-proven standard modules and components
guarantee– the service life of your machines through stable machinetechnology– cost-efficient solutions• Customised modification of existing processes enables you
to refine your production operations• Pre- and after-sales concepts support your processing
technology in the long term
• Our global service network provides you with rapid, targeted
technical support• Our global orientation always puts us close to our markets
and to our customers and their needs

KARL MAYER’s warp knitting machines with course-oriented
weft-insertion mainly offer YOUSUNG Industrial Fabrics efficiency
and diversity. The manufacturer’s product portfolio includes warp
knitted articles for a wide range of applications, such as roofings andtarpaulin materials.

ENGTEXEngtex AB was founded in 1939, and right from the start the compa­
ny relied on a fast adaptability to changing circumstances. In thisway, the enterprise offers products that perfectly satisfy the needsof the market. Moreover, the clients are supported by a highly
competent, efficient and flexible service in terms of research, designand development. For this purpose, Engtex makes use of its own
experience and know-how, but also of an extensive network. The
company’s diverse lines of business include Medical, Automotive,
Security and Reinforcement. Engtex is especially well known for its
cut protection solutions AVERTIC intended for protective work
clothing and building security.
Engtex uses the latest technologies for its communication andproduction.
The company’s innovative textile solutions are made on KARL
MAYER Raschel machines with and without course-oriented weft-­
insertion. Some models are equipped with substrate fabric feeding
systems. Besides, Engtex also uses tricot machines. The cooperation
between Engtex and KARL MAYER already started in the 1950s.

“KARL MAYER’s excellent knowledge and professionalism
helps us to be in forefront of technical textiles.”Patrik Johansson, CEO of Engtex ABKARL MAYER TECHNICAL TEXTILES

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INNOVATIVE PORTFOLIO AND AN
EXPERT DEVELOPMENT PARTNERINNOVATIVE MACHINE PORTFOLIO

WEFT-INSERTION WARP KNITTING MACHINESCOMPOSITE MACHINES

Our weft-insertion warp knitting machines can produce dense
fabrics as well as meshes with product-specific openings. And,of course, this is all done in the best quality and at optimum­productivity levels.
The textiles are usually made up of three yarn systems. The weftand filler yarns give the products their unique appearance. The
knitting yarns from another guide bar fix the textile according to
the construction.

Textile machines for non-crimp fabrics
Our machines are synonymous with maximum productivity andquality when producing multiaxial constructions. They have beendeveloped specifically for processing glass, carbon, aramid andother technical high-performance fibres.

Special features of the technology and advantages of themachines:• No waviness, since the yarn layers lie straight at angles of 0°
and 90°• Insertion and fixing of the weft yarns only at product-relevant
locations• Flexible product design, thanks to the Multispeed system andweft repeat functionality• High productivity through working widths of up to 6,800 mm
and maximum machine speeds of 2,000 rpm• Machine gauges of up to E 40, depending on the application• Wide range of applications because of the high variety of yarns
that can be processed

Special features of the technology and advantages of themachines:• Production of multilayered non-crimp fabrics (NCFs)• Possibility of processing continuous filament yarns or fibre tapes• Laying angles from +20° to –20° are possible• Fixing of the layers with a knitting yarn system• Combination of weft layers with other semi-finished products
Fibre-spreading assembly units for unidirectional fibre tapes
Machines for producing dry, unidirectional fibre tapes with low
weights per unit area from continuous filament yarns.
Special features of the technology and advantages of themachines:• Production of low weights per unit area
• High productivity• Production of tapes with widths of up to 800 mm• Modular machine concepts allow additional fixing means to be
introduced, such as adhesive meshes, powders and films

18 / 15TECHNICAL TEXTILES KARL MAYER

STRENGTHS OF THE TECHNO­
LOGY MADE BY KARL MAYERTECHNICAL TEXTILES:

Machines for thermoplastic tapes
Our solution for efficient production of continuous fibre-reinforced
thermoplastic tapes. The technology of the SIM.PLY enables acontinuous process control and uninterrupted production at highproduction speeds. Tapes with a width of up to 800 mm can beproduced. Thanks to the modular machine concept, the system canbe individually configured according to customers’ requirements.
Special features of the technology and advantages of themachines:• Modular machine design for spreading of fibres and impregnation
with thermoplastic matrix systems• High productivity of up to 10 m/min• 400–800 mm working width• Process temperature of up to 260 °C• Area weight 180–230 g/m²

• Highly productive processing of high-performance
fibres like polyester, glass, carbon, basalt andaramid• Maximum performance of the end products for
optimum use of the fibre properties, thanks to– homogeneous preparation– gentle handling of the fibres– defined laying and fixing• High flexibility of the layered structure through– simultaneous processing of different fibre materials– different laying angles• Combining several processing stages by processing
different types of materials (yarns, substrates,
powders, meshes)• Increased freedom when designing the end prod­
ucts by specifically manipulating the draping
characteristics• Quality assurance of the end products, thanks to
reproducible production processes and the use ofsuitable monitoring systems• Solid machine technology and cost efficiency by
combining industrially proven standard components
with ­customised solutions• The possibility of integrating KARL MAYER’ssolutions helps our customers to optimise their
entire production processKARL MAYER TECHNICAL TEXTILES

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OUR MACHINE PORTFOLIO
THE PERFECT SOLUTION FOR ALL YO
AUTOMOTIVEWEFT-INSERTION MACHINESWEFTTRONIC® II HKSTM WEFTWEFTTRONIC® II RSPWEFTTRONIC® II RS

WEFTTRONIC® II G

RS MSUS – HG

RS MSUS – V

COMPOSITE MACHINES

BIAXTRONIC® CO

COP BIAX 2

COP MAX 4

MAXTRONIC®

COP MAX 5

UD 700/UD 500

SIM.PLY

BUILDING AND­C ONSTRUCTION

TRANSPORTATIONANDAEROSPACE18 / 17TECHNICAL TEXTILES KARL MAYER

UR REQUIREMENTS
RENEWABLE
ENERGY

SPORTSEQUIPMENTPERSONALPROTECTION

ADVERTISING

MEDICAL­T ECHNOLOGYINFRASTRUCTURE

APPARELAND
HOME TEXTILES

REINFORCEMENT
AND COATINGSUBSTRATESKARL MAYER Worldwide© KARL MAYER STOLL Textilmaschinenfabrik GmbH
Industriestraße 1 . 63179 Obertshausen . Germany
www.karlmayer.com
The information provided in this document contains merely general descriptions or characteristics of which may change as a result offurther development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in theterms of contract. Availability and technical specifications are subject to change without notice. All rights reserved.

We-A-1155/2/02/20

Europe	Germany Obertshausen, Chemnitz, Selbitz, Frankfurt am Main, Reutlingen, Waldmünchen
Italy Mezzolombardo, Carpi Switzerland Oberbüren UK Nottingham
Asia
Bangladesh Dhaka China Changzhou, Hong Kong India Ahmedabad, Delhi Japan Fukui
North America USA Greensboro