Applied Sciences

Applied Sciences

Overlap Fix - High performance textile structures for composites through open reed weaving


Ref.-Nr. 3898

Due to the limited needle shifting in state of the art weaving systems, current textile products present many limitations regarding their effectiveness and lifetime. Fiber properties are highly dependent on loading direction and even a small angle deviation can lead into a significant performance drop. Only small areas of multiaxial fabric are possible with the existing production methods and the load path is constantly interrupted.

Inventors of the RWTH Aachen University filed a patent relating the production of the multiaxial enforcement fabrics for textile composites with ORW (Open Reed Weave). To avoid load path interruptions in composites with textile enforcement, an overlapping of two yarn systems in the textile, by means of a special weaving pattern, leads to continuous load path in bias direction, reaching a “Triaxial” fabric, which is the main approach of the investigation.

The Angle of additional reinforcement direction is adjustable and the calculated necessary overlapping is 16.28 mm length. The system´s capability was verified by conducting three-point bending tests. These are performed varying the overlapping length, testing carbon and glass fibers and using reference samples as follows: [0/90°] fabrics and [0/90/45°] fabrics with continuous reinforcement. The results were successful in all cases.


The developed new textile structure has a high potential for reinforcing shell components with complex load cases. By the additional load bearing direction within the fabric the general part stability can be increased significantly where usually, +/-45° layers have to be used. Especially for complex geometries where woven fabrics have to be used due to their good drapeability these +/-45° layers cause a lot of waste.

By using the developed triaxial fabrics this waste can be reduced by about 25 %. Additionally, the number of necessary process steps for the layup can be reduced due to the integrated fiber orientations.

Further investigations are also needed on this field. The machine setup has to be adapted for being able to realize the developed weave design. Additionally, more material combinations have to be investigated. For these materials, an extensive characterization of the fabric and composite properties is required for an industrial application. Based on these data, rules for a most efficient fabric design with optimized material efficiency have to be established.

Current Status

An international PCT patent application has been filed. Further International applications are still possible. The invention could prove its feasibility in numerous experiments.

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