Apex Mills

Case studies

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  • Style: ALTO

    Industry type: Aerospace & Defense

    Fabric types:
    MESH/NETTING

    Design Goal:
    INNOVATIVE

    Content:
    Nylon

    Weight: 0.28

    Aerospace/Composite Materials

    PROBLEM SHARED

    A manufacturer of composite materials for aerospace structures was experiencing shrinkage in the netting substrate that carried an adhesive used to join aircraft components.

     

    PROBLEM SOLVED

    Apex analyzed the directional tensions used in applying the adhesive to the current netting substrate. The solution to the shrinkage problem was eliminated when we modified the temperatures and finishing tensions applied to the fabric.


    RESULTS REALIZED

    The newly improved fabric no longer shrank and the customer no longer was faced with potentially failing composite parts.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: D51A

    Industry type: Safety

    Fabric types:
    MESH/NETTING

    Design Goal:
    PERFORMANCE

    Content:
    100% Polyester

    Weight: 3.28 +/- 5%

    Recreational/Sporting

    PROBLEM SHARED

    A leading supplier of life jackets was experiencing two problems with the fabric it was using as a liner. The mesh was too coarse and abrasive against skin, and the thickness of the fabric made it difficult for the sewing operators to work with, ultimately reducing production efficiency. An additional consideration was that the fabric required Underwriters Laboratory approval.

     

    PROBLEM SOLVED

    After extensive consultations with the customer, the existing fabric was knitted on a coarse gauge machine with large openings, thick stitches, and heavy yarns — the combination of which made for a very rough fabric. Using a finer gauge knitting machine and lighter weight yarns, we produced a smoother mesh with a smaller opening that still allowed for ample water drainage. The fabric was dyed and finished to meet UL standards and was a less expensive alternative to the original mesh.

     

    RESULTS REALIZED

    The customer evaluated, approved and adopted the fabric, which continues to remain less expensive than the cost of the original fabric.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: DNB145

    Industry type: Government

    Fabric types:
    3D SPACERS

    Content:
    100% Polyester featuring AMY/Sorbtek

    Weight: 8.10 +/-10%

    National Police Force

    PROBLEM SHARED

    A world renowned police force needed a performance fabric to be used as the lining in their military grade vests. The current fabric was heavy and retained moisture and odor, making it uncomfortable and unhealthy as it preserved bacteria caused from the moisture.

     

    PROBLEM SOLVED

    As a leading specialist in manufacturing textiles that adhere to military specifications, Apex Mills was quick to jump into action. We were able to produce a 100% polyester spacer fabric featuring antimicrobial and permanent moisture management properties that perform six times faster than other moisture wicking fabrics.

     

    RESULTS REALIZED

    By incorporating this fabric into their lifesaving ballistic vest, our customer was able to produce a lightweight and comfortable vest with adjustable straps to ensure a proper fit and promote minimal shifting during wear. This vest became standard issue for the force and received accolades from those who brave the elements from arctic blasts to extreme heat to save the lives of others.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: DNB198A

    Industry type: Orthopedic

    Fabric types:
    3D SPACERS

    Design Goal:
    ENGINEERED

    Content:
    100% Polyester featuring AMY/Sorbtek

    Weight: 8.0 +/- 10%

    Orthopedic Supplies

    Problem Shared

    A reputable company in the orthopedic industry wanted to produce a high-grade arm sling to increase comfort for the patient and enhance innate properties to the sling, for example make it less prone to absorb bacteria from sweat and dirt. As a US manufacturer, they sought a supplier with the same values they held and manufacturing facilities in the US.

     

    Problem Solved

    Analyzing the problem with the customer, Apex Mills’ fabric specialists developed a lightweight 3D spacer fabric with a textured polyester surface and an anti-microbial, moisture wicking backing.

    The unique yarn construction paired with the ability to use two different fabrics with a springy monofilament in-between, enabled our customer to achieve their objectives while keeping the cost of production down.

     

    Results Realized

    The new sling proved successful, yielding positive feedback from patients and orthopedic specialists alike. As a result of the accolades received, the sling has become an approved item by Medicare and Apex Mills is partnering with the customer in their product development planning. 

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: DNB59

    Industry type: Furniture

    Fabric types:
    3D SPACERS

    Content:
    100% Polyester

    Weight: 12.25 +/- 15%

    Furniture

    PROBLEM SHARED

    A global manufacturer of office furniture wanted a transparent, cushioned fabric that met the ergonomic and cosmetic needs of their newly fashioned seating solution.

     

    PROBLEM SOLVED

    Upon partnering with the customer's product engineers and design team, we first gained a comprehensive understanding of their design goals. We then developed a 3-demensional fabric with the resiliency, stretch and sheerness that achieved each of our customer's goals. We developed a second component spacer fabric knit with clear yarn, which further enhanced the comfort, airflow and transparency of the chair, thereby exceeding our client's expectations

     

    RESULTS REALIZED

    Pleased with the fabric's performance and aesthetics, the company integrated the fabric into their product mix, showcasing its forward thinking design. Within months of bringing the product to market, it became one of the company's best-selling designs. 

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: NK50A

    Industry type: Apparel & Footwear

    Fabric types:
    SOLID KNITS

    Content:
    Polyester

    Weight: 5.4 +/- 15%

    Footwear

    PROBLEM SHARED

    A newly founded company with an expertise in footwear linings had a concept for a new shoe lining which would produce less friction between the sock and the shoe and thus keep the foot cooler.


    PROBLEM SOLVED

    After extensive consultations with the customer, we determined that the application required the creation of a soft, smooth fabric that simultaneously could withstand the footwear industry's abrasion and wear standards. With special attention to the filament count of the yarn, we produced a fabric utilizing texturized polyester, which achieved the desired results and met the existing standards. The problem we ran into was that the fabric was too heavy and cost prohibitive to produce. A modification of the knitting structure using the same yarn yielded a fabric with similar performance characteristics at a marketable price.

     

    RESULTS REALIZED

    Our customer adopted the fabric and currently offers it as one of the leading performance footwear linings available on the market today.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: NW96

    Industry type: Medical

    Fabric types:
    MESH/NETTING

    Content:
    Polyester

    Weight: 9.6 +/- 15%

    Institutional/Home Healthcare

    PROBLEM SHARED

    One of the nation's largest suppliers of patient lift slings had a fabric problem that was creating a potentially dangerous condition for the patients using them.

     

    PROBLEM SOLVED

    After analyzing the four main requirements of the sling—fabric strength, stability, drainage and surface smoothness—we concluded that the fabric construction and the yarn choice required reengineering. We designed a stabilized, non-stretch fabric using high tenacity yarn chosen for its strength. The fabric was knitted to create a smooth, non-abrasive seating surface that promoted drainage. The new textile was also rated 30% stronger. All of this was accomplished with no price increase. An option to use an anti-microbial finish offered the added feature of improved sanitary conditions.

     

    RESULTS REALIZED

    The patient lift sling supplier replaced the fabric of the sling seat, and significantly reduced their risk exposure while at the same time offering a more comfortable seating surface.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: ND29

    Industry type: Automotive

    Fabric types:
    SOLID KNITS

    Design Goal:
    PERFORMANCE

    Content:
    Polyester

    Weight: 3.2

    Automotive

    PROBLEM SHARED

    A manufacturer of automotive wiping cloths felt "locked in" to their existing fabric supplier. They were dissatisfied with their suppliers' responsiveness and pricing.


    PROBLEM SOLVED

    We identified each of the fabric characteristics that were important to the end user. This was followed by a thorough analysis of the relevant patent. Using its own previously developed knitting techniques, we were able to submit to the customer a new fabric, which addressed the desired characteristics, but avoided any patent conflict. 

    Apex worked together with the manufacturer to design and create a less expensive fabric that offers the same functionality, but doesn't infringe on the patent.


    RESULTS REALIZED

    The manufacturer is now no longer constrained by the patented fabric and is able to gain greater market share with the new, less expensive fabric.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: PL85

    Industry type: Filters & Screens

    Fabric types:
    MESH/NETTING

    Design Goal:
    INNOVATIVE

    Content:
    Specialty Yarn

    Weight: 4

    Aquaculture

    PROBLEM SHARED

    A clam farmer was suffering a significant loss of clams he was growing in bags placed on the sea floor. Predatory animals were chewing through the mesh in order to feed on the immature clams. Prior attempts to strengthen the mesh, while successful, were not environmentally compatible.

     

    PROBLEM SOLVED

    Apex analyzed the strength of the current mesh the clam farmer was using, with a special attention paid to the tenacity of the yarns being used.

    Apex then created a fabric identical to the one being used, however, incorporated a high tenacity monofilament yarn into the mesh.

     

    RESULTS REALIZED

    With this newly developed fabric, strengthened by a yarn similar to fishing line, the customer is now positioned to employ clam bags offering significantly lower clam loss.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: Bioweb

    Industry type: Environmental

    Fabric types:
    MESH/NETTING

    Design Goal:
    INNOVATIVE

    Content:
    Polyester

    Weight: 11.5

    Environmental

    PROBLEM SHARED

    The City of New York's water treatment facility was using a technology that was limiting the ability to remove nitrogen from waste water, a process which allows the water to return to streams and rivers.


    PROBLEM SOLVED

    Understanding that the effectiveness of the media was first and foremost dependant on the amount of bio-mass given opportunity to grow, we concluded that the fabric must at the same time balance a maximization of surface area and porosity for water flow.

    After several different designs were evaluated, we developed and created an innovative, highly fibrous fabric, exhibiting more surface area than any it had previously produced, that more effectively removed nitrogen from waste water.


    RESULTS REALIZED

    Apex's patented Bioweb system not only achieved the customer's target effectiveness and was environmentally safe, but also offered the added benefit reducing the sludge bi-product. The Bioweb system addresses the needs of growing population centers. It can be installed in existing water processing facilities without the need for plant expansion.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: XT54

    Industry type: Military

    Fabric types:
    MESH/NETTING

    Design Goal:
    PERFORMANCE

    Content:
    Blend

    Weight: 0.6

    Military/ Government Contract

    PROBLEM SHARED

    A military contractor was in need of a high strength, light-weight fabric for a new counter-chemical/ biological warfare garment utilizing nanotechnology. This fabric was needed as part of a special test to take place in Germany within two weeks.


    PROBLEM SOLVED

    We took into account the customer's tenacity requirements and thickness limitations in the process of selecting the most appropriate specialty yarn for the application. This yarn was then modeled into a fabric with the knit construction which addressed the customer's other functional needs to ensure the weight requirements would be met.

    After collaboration with the client, we developed an ultra-high strength yarn using a unique knitting pattern that met the customer's performance requirements. Once designed, we warped, knitted and finished the material in 8 days, in time for the contractor's trip to Germany.


    RESULTS REALIZED

    After collaboration with the client, we developed an ultra-high strength yarn using a unique knitting pattern that met the customer's performance requirements. Once designed, we warped, knitted and finished the material in 8 days, in time for the contractor's trip to Germany.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: NK47A

    Industry type: Filters & Screens

    Fabric types:
    SOLID KNITS

    Design Goal:
    INNOVATIVE

    Content:
    Polyester

    Weight: 2.6

    Filtration

    PROBLEM SHARED

    The fabric used by a manufacturer of a reverse osmosis filtration system was limiting the efficiency of the process due to the water being dispersed in multiple, unrestrained directions.

     

    PROBLEM SOLVED

    The construction of the fabric used in the filter did not control the dispersion of water in a single direction. A new construction was needed to guide the liquid flow.

    The fabric was redesigned to create a channel system that funneled the water in a single direction.


    RESULTS REALIZED

    By controlling the direction of water dispersion, the new fabric considerably increased the filter's efficiency.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: NH43

    Industry type: Safety

    Fabric types:
    MESH/NETTING

    Design Goal:
    PERFORMANCE

    Content:
    Polyester

    Weight: 2.75

    Safety/ Transportation

    PROBLEM SHARED

    One of the largest manufacturers of reflective tapes used by police, firefighters and other safety personnel, needed a substrate fabric incorporating a costly flame retardant treatment to meet its flammability standards.

    PROBLEM SOLVED

    The specification was reviewed focusing on the flame retardant characteristics of the component yarns, finishes and reflective substances being applied by the customer. With the customer's cooperation, untreated versions of the substrate were tested.

    When the inherent flammability characteristics of the polyester substrate fabric were combined with those of the customer's reflective substances, the fabric passed all required tests. The costly flame retardant treatment was found unnecessary.


    RESULTS REALIZED

    The resulting simplification of the legacy specification allowed the customer a significant cost reduction for its substrate fabric.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development
  • Style: PV57

    Industry type: Consumer Products / Electronics

    Fabric types:
    SOLID KNITS

    Design Goal:
    INNOVATIVE

    Content:
    100% Vinyl

    Weight: 21 +

    Consumer Products / Electronics

    Problem Shared

    A leading designer of high-end woven vinyl accessories and home furnishings wanted to augment their product line with an alternative to woven goods. Intrigued by the durability of the knitting process, they sought to reduce the amount of fraying and fabric loosening that sometimes occurs in weaves.


    Problem Solved

    Using a variation of the vinyl yarn currently used by the designer, Apex Mills engineers were able to modify the knitting machines and process to accommodate the heavier and less pliable vinyl yarn. Working together, we were able to maintain the unique fabric properties in which the company has built their reputation.

     

    Results Realized

    Not only was this luxury home accessories and furnishings manufacturer able to extend the depth of their existing product line, they were able to expand the breadth of products offered because of the increased strength and stability provided by the custom tailored warp knit process.

    To browse all of our textiles, visit the Textile Gallery
    Need more guidance? START HERE with our Custom Textile Development

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