Apex Mills

ENGINEERED INNOVATIVE PERFORMANCE

Collaboration and precision are vital to the success of Apex Mills. Knowing the full extent of the challenges our customers face allows us to solve them with technical precision. Here's an example: A leading office furniture manufacturer came to us with a revolutionary new chair concept and needed a revolutionary new fabric for it. Our team met with their chief designer and engineer to thoroughly understand their aesthetic and performance goals. The design of the chair required a 3D spacer knit with a specific elongation parameter, but one that could not buckle or pucker. And, while they didn't want the chair to look like home furnishings, they also did not want it to appear too high tech. [+][-] We developed a preliminary design with the characteristics and properties to address their needs. After several iterations we produced exactly what the customer had envisioned for, what is today, one of their top selling office chairs. To Apex Mills, engineering is collaboration. It's the process of turning the customer's exact problem into our own challenge, then working quickly to create a precise solution. Nobody works more closely with customers than Apex Mills.
ENGINEERED TEXTILES CASE STUDIES |
  • Style: NK50A

    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.

  • Style: ND29

    Design Goal:
    PERFORMANCE

    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.

  • Style: NK47A

    Design Goal:
    INNOVATIVE

    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.

  • Style: PV57

    Design Goal:
    INNOVATIVE

    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.

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