3D braided fabrics are fabrics in which yarn runs through the
braid
A braid (also referred to as a plait) is a complex structure or pattern formed by interlacing two or more strands of flexible material such as textile yarns, wire, or hair.
The simplest and most common version is a flat, solid, three-strande ...
in all three directions, formed by inter-plaiting three orthogonal sets of
yarn
Yarn is a long continuous length of interlocked fibres, used in sewing, crocheting, knitting, weaving, embroidery, ropemaking, and the production of textiles. Thread is a type of yarn intended for sewing by hand or machine. Modern manufact ...
.
[>M, Subramanian Senthil Kannan, and Kumaravel S (2008). "A Comprehensive Look at 3-D Fabrics." The Indian Textile Journal.] The fiber architecture of three-dimensional braided fabrics provides high strength, stiffness, and structural integrity, making them suitable for a wide array of applications. 3D fabrics can be produced via
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. Other methods are knitting, crocheting, felting, and braiding or plaiting. The longitudinal th ...
,
knitting
Knitting is a method by which yarn is manipulated to create a textile, or fabric. It is used to create many types of garments. Knitting may be done by hand or by machine.
Knitting creates stitches: loops of yarn in a row, either flat or i ...
, and non-weaving processes.
History
Three-dimensional braiding is among the oldest and most important of textile processes, transforming small natural fibers into more functional forms. Fabrics used in 3D braiding, such as
rope
A rope is a group of yarns, plies, fibres, or strands that are twisted or braided together into a larger and stronger form. Ropes have tensile strength and so can be used for dragging and lifting. Rope is thicker and stronger than similarly ...
, have been used since 4,000 BC.
In 1748, patents for the first 3D braiding machines were initiated in England. Most 3D
braiding machine
A braiding machine is a device that interlaces three or more strands of yarn or wire to create a variety of materials, including rope, reinforced hose, covered power cords, and some types of lace. Braiding materials include natural and synthetic ...
s of the time were developed by modifying 2D braiding machines. In 1767, the first braiding machines which produced two-dimensional fabrics whose properties were different from 3D fabrics appeared in Germany. During the 1960s, the U.S. Government, as well as industrial and academic researchers, developed 3D braiding machines for use in producing composite material preforms, such as
carbon fiber
Carbon fiber-reinforced polymers (American English), carbon-fibre-reinforced polymers (Commonwealth English), carbon-fiber-reinforced plastics, carbon-fiber reinforced-thermoplastic (CFRP, CRP, CFRTP), also known as carbon fiber, carbon compo ...
composites.
[>Branscomb, David, David Beale, and Royall Broughton(2013). "New Directions in Braiding." The Journal of Engineered Fibers and Fabrics (JEFF) 8.2: 1-24.]
Properties
3D braids show improved mechanical and structural properties. An important characteristic of 3D braids is their ability to form a variety of complex shapes; the direct manufacturing of complex structural shapes helps to eliminate the process of cutting to form joints, overlaps, and splices. 3D braided fabrics have high torsional stability and structural integrity.
[>Du, G.-W., and F. K. Ko(1993). "Unit Cell Geometry of 3D Braided Structures." ]Journal of Reinforced Plastics and Composites
The ''Journal of Reinforced Plastics and Composites'' is a peer-reviewed scientific journal that covers research in the field of materials science, especially plastics and composites. The editor-in-chief is G. Springer (Stanford University). I ...
12.7: 752-68.
Manufacturing Techniques
A track plate is kept at the bottom of the machine. Packages, which supply axial yarns, are kept beneath the track plate.
Bobbin
A bobbin or spool is a spindle or cylinder, with or without flanges, on which yarn, thread, wire, tape or film is wound. Bobbins are typically found in industrial textile machinery, as well as in sewing machines, fishing reels, tape measure ...
s are mounted on the carrier, which is pushed by
horn gear
A braiding machine is a device that interlaces three or more strands of yarn or wire to create a variety of materials, including rope, reinforced hose, covered power cords, and some types of lace. Braiding materials include natural and synthetic ...
s over the track plate. Braiding yarns are fed from these bobbins. The relative motion of the braiding yarns and the axial yarn determines the pattern and the structure of the braid.
[/>
The 3D braiding process is a minor modification of 2D braiding process, where the standing ends are added to the braiding yarns that are moving. The most important 3D braiding techniques are discussed below.][>]
Circular braiding and over-braiding
In circular braiding, the bobbins (with opposite directions of rotation) move in two concentric orbits. The two orbits interfere to form dephased sinusoidal
A sine wave, sinusoidal wave, or just sinusoid is a mathematical curve defined in terms of the '' sine'' trigonometric function, of which it is the graph. It is a type of continuous wave and also a smooth periodic function. It occurs often in m ...
oscillations that determine the thread's pattern and crossing point. At this crossing point, the bobbins change their path to produce the upper and inner side of the braid. Generally, the circular braiding process produces braids with rotational symmetry
Rotational symmetry, also known as radial symmetry in geometry, is the property a shape has when it looks the same after some rotation by a partial turn. An object's degree of rotational symmetry is the number of distinct orientations in which i ...
. The over-braiding process follows the same principle as the circular braiding process, but the only modification is that the crossing point is located at the center.[/>
]
Four-step braiding process
In this process, the bobbins move on the X and Y axes, which are mutually perpendicular to each other. In each step, the bobbins move to the neighboring crossing point in both axis and both directions, and stop for a specific interval of time. Basic arrangement of the braiding field is obtained after a minimum of four steps. This method produces braids which have a constant cross section.[/>
]
Two-step braiding process
In the two-step braiding process, the bobbins move continuously without stopping. They move on the track plate through the complete structure and around the standing ends, such that the movements of bobbins are faster when compared to the four-step braiding process. The bobbins can move only in two directions, so the process is called the two-step braiding process.[/>
]
3D rotary braiding
The 3D rotary braiding process consists of base plates with horn gear
A braiding machine is a device that interlaces three or more strands of yarn or wire to create a variety of materials, including rope, reinforced hose, covered power cords, and some types of lace. Braiding materials include natural and synthetic ...
s and mobile bobbins arranged upon them. Switches are used to control the position of the threads and horn gears.[/>
]
Applications of 3D braided fabrics
3D braided fabrics have found applications in areas including medicine, aerospace
Aerospace is a term used to collectively refer to the atmosphere and outer space. Aerospace activity is very diverse, with a multitude of commercial, industrial and military applications. Aerospace engineering consists of aeronautics and astrona ...
, automobiles, train components, and reinforced hoses.[>Drechsler.K (1999). "3-D Textile Reinforced Composites for the Transportation Industry." 3-D Textile Reinforcements in Composite Materials. 43-66.] The initial development of 3D braided fabrics came from the composite and medical industries. 3D braided fabrics can be manufactured in myriad varieties of cross-sections, and their near-net complex shapes made it possible to design very specialized products for both industries.[>Tong, Liyong, Adrian P. Mouritz, and Michael K. Bannister (2002). 3D Fiber Reinforced Polymer Composites.137-146.]
In helicopters, typical structural components like beams, sandwich structures, frames, and panels are manufactured using 3D braided profiles. Similarly, 3D fabrics are used to manufacture complex beam structures and floor panels in passenger cars. For train structures, different components manufactured from 3D braided profiles include the roof panel, interior components, side panels, and body structures.
In medicine
In the medical industry, 3D braided fabrics find applications in stent graft
In medicine, a stent is a metal or plastic tube inserted into the lumen of an anatomic vessel or duct to keep the passageway open, and stenting is the placement of a stent. A wide variety of stents are used for different purposes, from expandab ...
s, bifurcated stents, arm and leg prosthetics
In medicine, a prosthesis (plural: prostheses; from grc, πρόσθεσις, prósthesis, addition, application, attachment), or a prosthetic implant, is an artificial device that replaces a missing body part, which may be lost through trau ...
, and braided sutures. Surgeons initially used two separate implant procedures for bifurcation stenosis treatment, which was time-consuming. With the advent of 3D braided fabric, multiple dendrite circular braids were produced for bifurcation stenosis treatment, which is flexible and less time-consuming. With multiple tubular braided structures, various cardiovascular implants can be produced.[>Schreiber, F., F. K. Ko, H. J. Yang, E. Amalric, and T. Gries (2009). Proc. of 17th International Conference on Composite Materials, UK, Edinburg.]
In manufacturing of reinforced composite
Braiding is a unique technology for producing high-volume, yet low-cost, composites.[>Branscomb, David, David Beale, and Royall Broughton. (2013). ("New Directions in Braiding") ("Journal of Engineered Fibers and Fabrics 8.2.")] With 3D braided fabric as reinforcement, complex shapes can be manufactured inexpensively. The 3D braided reinforced composites also exhibit high delamination
Delamination is a mode of failure where a material fractures into layers. A variety of materials including laminate composites and concrete can fail by delamination. Processing can create layers in materials such as steel formed by rolling and ...
resistance.[>Mouritz, A.p., M.k. Bannister, P.j. Falzon, and K.h. Leong(1999). ("Review of Applications for Advanced Three dimensional Fiber Textile Composites") Composites Part A: Applied Science and Manufacturing 30.12: 1445-461.]
References
External links
*
The Indian Textile Journal
{{Braiding
Textiles
Textile techniques