Three-Dimensional (3-D) Form Felting Machine & Process

By Deborah Loxam-Kohl

World Wool Award Recipient:Concept, Innovation & Extension

The Three-Dimensional Form Felting Machine & Process:

• produces form directly from raw material

• utilizes the natural ability of wool to felt

• operates using the wet-felting method

• employs heat, moisture and agitation

• uses pure wool, or wool blended with natural and/or synthetic fibres

Qualities of felted wool

Pleasing to touchHolds colour beautifully Warm and comfortable

Consistent nape Cuts without unravelling Durable and protective

Wicks moistureRetains its insulating abilities even when wet

Insulates against temperature, sound, and vibration Softness and lightness like silk, or thickness and rigidity like

leather

All are desirable characteristics that lend themselves to domestic, commercial and industrial applications.

The quality of felt produced using the machine:

• smooth surface texture • uniform wall thickness• consistent density• strong fibre matrix • structural integrity• excellent surface wear• resistance to further

shrinkage • concave or convex forms

Advantages for the consumer:

expresses the warmth, comfort and ease of wear associated with wool

access to unique products that were previously unavailable

simplified care instructions and reduced fibre shrinkage

long wearing and non-pilling made from a renewable

natural resource that is non-toxic and eco friendly

Commercial benefits for the retailer:

a unique product not found elsewhere upholds the aesthetic qualities of wool desired by the

consumer a product requiring less maintenance and care for the

consumer a material with structural integrity, stability and resistance

to surface wear reduction in consumer returns due to shrinkage or

complex care instructions reduction in inventory losses and labour costs related to

customer returns increased customer confidence in product

Benefits to the wool industry:

the ability to position wool within the non-wovens industry the ability to compete with synthetic-fibre, non-woven

products a product with comparable physical properties to heat-

pressed spun-polyester fibre products an increased efficiency in production producing felt components directly from wool batting, rather

than having to construct forms from flat felt pieces significant improvements in product quality and design when

applying the technology to existing manufacturing methods a process that lends itself to mass-manufacturing methods an affordable and easy to integrate addition to existing felt

manufacturing systems

An example of products made from felt:

• fashion accessories: hats, boots, shoes, and handbags • insulating panels in automobiles that protect against

sound, vibration and temperature• air, oil and water filters, wicks and gaskets in automobiles• orthopedic insoles• stereo speaker cones• acoustic wall and ceiling panels

Next to paper, felt is the second most ubiquitous material in our surroundings, however, it is usually hidden

beneath the surface of other materials.

Current methods of manufacture:

• Die-cutting pattern pieces of flat felt, which are scored, folded, and glued or sewn together to create form.

• Turning thick pieces of flat felt on a lathe to create tubes, which are cut and bent into circles, the ends sewn together to create ‘o’ rings.

• Injecting fibres with resin and pressing them into a mould.

In each case, a 3-D felted-wool form could be produced: • simplifying the method of manufacture• providing a product with more structural integrity• eliminating the need for chemical stiffeners

Potential applications of the technology:

• Moulded luggage, computer and archival storage cases.

• Non-obtrusive, aesthetically engineered shock-absorbent pads for protection in sports, physiotherapy, and the design of prosthetics.

• Lightweight, custom moulded packaging to fit electronics and digital devices.

• Shock dampening applications in computer equipment.

Innovative applications:

• Engineered pressure-point pads for astronaut suits in zero gravity environments (NASA).

• Engineered felted-wool cuff with integrated computation device (Hewlett-Package).

• Recycled, macerated wool fibres in a reconstituted liquid medium, cast into forms for insulation and packaging, or components.

Blended with other fibres:

• Properties of wool are enhanced and transformed.

• Research and testing indicate both natural and artificial fibres can be integrated into the wool felting process.

• A new material emerges that retains the qualities of wool felt, while exhibiting new characteristics.

• Potential exists to utilize recycled fibres from garment industry.

Benefits of the Felting Machine & Process:

• produces a superior quality felt• produces a 3-D form, in-the-round, directly from raw materials• eliminates die-cutting pattern pieces from flat felt, that are

scored, folded, and glued or sewn together to produce form • makes the manufacture of forms more efficient• forms retain their shape without the use of stiffeners or

adhesives• applicable to industries with stringent purity regulations

requiring natural, non-toxic, hypoallergenic, or environmentally friendly processes or materials

ie: soundproof wall panels for residential, commercial and industrial uses; garments or accessories worn on the body

The 3-D Felting Machine and Process

• an innovative solution to the production of felted-wool forms

• represents a technical breakthrough that adds to our knowledge and understanding of the properties of wool and its applications

• research and development will reveal its value as an innovative method of manufacture for non-woven goods

• when applied to various industries, will initiate the development of groundbreaking new products

• has the potential to increase the development and distribution of wool through widespread applications in domestic, commercial and industrial applications