The needling process also known as “needle punching,” was developed as a new generation felt process as a method of forming textiles or fabrics directly joining fibers and bypassing the need for yarn. The term “nonwoven” was created as a result of this manufacturing technique producing fabrics without a weaving or knitting process. With the development of synthetic fibers, the technology became further established within the textile industry. Synthetic fibers, having a “smooth” structure, needed a manner of entanglement different than traditional felting methods requiring wool fibers.
Fibers are layered into a loose matting structure and then entangled by the use of needles penetrating through the mass of fibers. The needles are made with “barbs” that hook or latch onto the fibers interlocking them as the needles move continuously in an up and down fashion. There are generally two or more needling positions. The initial needling or “tacking” is to entangle the fibrous layers into one. Further needling steps form the fabric to its desired density and specification.
US Felt’s needling process incorporates standard technology with specially designed equipment. As a result, US Felt can custom engineer solutions for a variety of needs and to meet very exact requirements. Many products are based upon SAE Felt standards and textiles as measured by ASTM guidelines. Applications often determine the form and function of the product as specified by our customers. US Felt is uniquely prepared to develop and deliver the nonwoven fabric or felt tailored to your exact design.