Patent ID: 8689414

Claim:
A method for producing a multi-layer fabric, said method comprising the steps of: coating separate yarns of a first set of yarns with a removable coating with a first thickness such that a coating diameter of each of the separate yarns is at least two times a diameter of each of the separate yarns; controlling tension in each yarn of the first set of yarns; weaving a first fabric layer with the first set of yarns in a braid weave architecture with balanced crimp contents; applying a first measured crimp by said weaving step in each yarn of the first set of yarns wherein the thickness of the removable coating alters a crimp content of each yarn of the first set of yarns when woven; coating separate yarns of a second set of yarns with a removable coating with a second thickness such that a coating diameter of each of the separate yarns is at least two times a diameter of each of the separate yarns of the second set of yarns; controlling tension in each yarn of the second set of yarns; weaving a second fabric layer with the second set of yarns in a plain weave architecture with balanced crimp contents; applying a second measured crimp in each yarn of the second set of yarns by said step of weaving the second fabric layer wherein the thickness of the removable coating alters a crimp content of each yarn of the second set of yarns when woven; and removing the coating from the first set and second set of yarns.