3D Spacer Fabrics –
Innovative, Engineered, and Performance Driven

3D spacers, also known as “spacer” fabrics, are three-dimensional textiles with two outer layers of material surrounding a looping yarn (or pile) structure to provide key performance advantages.

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The three-dimensional nature of these fabrics offers a range of interesting properties, including absorbency, breathability, cushion, loft, resilience, softness, and visual appeal. 3D spacer fabrics are commonly used in automotive materials, filtration, footwear, furniture, geotextiles, medical materials, military and tactical apparel, and sportswear.

A Look Inside 3D Spacer Fabrics

Each layer of a 3D spacer fabric can provide unique characteristics, which gives the textile designer flexibility in terms of functionality. When specifying 3D spacer fabrics, there are three critical variables to consider:

1. Fabric construction: The face and back of the fabric can be a solid knit or a mesh design. A mesh face allows for more airflow, while a solid knit, for example, enables the textile designer to apply a performance-enhancing additive to the center fibers, perhaps for insulation or molding properties. The fabric’s thickness can also be modified based on the application. For example, a thicker spacer fabric could provide fortified cushioning or added insulation.

2. Yarn selection: The textile designer may choose polyester or nylon for strength and durability. A silver, copper, or zinc yarn may be selected to provide antimicrobial attributes. Yarns can also be selected to achieve sustainability goals, e.g., using yarns made from recycled plastic chips or even biodegradable materials.

3. Finishing: The process/processes used to finish the fabric is vital to consider. Finishes can enhance utility, texture, and color, among other key characteristics. The finishing step(s) allows the designer to fine-tune the material to maximize its performance based on the intended end-use. (For a deeper dive into textile finishing, please check out our “Guide to Fabric Finishes.”)

How Are 3D Spacer Fabrics Made?

3D spacer fabrics are made on double-needle-bar (DNB) machines. These knitting machines have two independent needle-bar systems, each used to knit a side of the fabric. The machine creates the innermost layer by traversing spacer yarns between the outer fabric faces. Monofilament (single strand/thread) yarns are often used for the innermost (or pile) layer, as they are more resilient and stiffer, which allows for greater separation between the two outer layers of the fabric. Multifilament (multiple strands/threads braided together) yarns can also be used, but they are softer and limit the thickness of the spacer fabric to about 4mm.

Physical Properties and Benefits of 3D Spacer Fabrics

The unconventional three-layer structure of 3D spacer fabrics provides essential benefits, including:

• Breathability: The open, airy structure minimizes weight. The gaps in the fabric allow excellent airflow, improving comfort and reducing heat buildup.
• Cushion and impact resistance: The spacer structure offers shock absorption and cushioning.
• Durability and strength: 3D spacer fabrics are strong and wear-resistant, particularly when made from synthetic fibers like polyester.
• Moisture management: 3D spacer fabrics made from polyester and nylon wick away moisture, keeping surfaces dry.
• Sustainability: When made from recycled materials or biopolymers, 3D spacer fabrics can be designed to enhance sustainability

Customization Offers More Benefits

Several aspects of 3D spacer fabrics can be designed to provide enhanced performance for specific applications:

• Thickness: The thickness of the spacer fabric can be adjusted by altering the distance between the outer layers to meet the cushioning, strength, or thermal insulation application requirements.
• Material: 3D spacer fabrics can be made from many different fiber types, allowing the textile designer to meet multiple performance attributes, such as breathability, durability, and eco-friendliness.
• Pattern: The knitting structure can enhance the fabric’s aesthetic, flexibility, and stretch. These characteristics (and others) can be optimized by adjusting the pattern used to make each layer of the spacer fabric.
• Shape and size: 3D spacer fabrics can be cut, molded, or sewn into intricate shapes, making them ideal for unique designs like medical braces, orthopedic supports, arch-supporting insoles, or automotive seat panels.

Customized 3D spacer fabrics can deliver enhanced performance in areas such as:

• Breathability/ventilation
• Cushioning and support
• Fire resistance
• Moisture management
• Thermal regulation

Dyeing and Finishing for 3D Spacer Fabrics

Apex Mills delivers advanced, customized 3D spacer fabrics for various industries and applications, including aerospace, automotive, medical, military, and tactical apparel. Our 3D knitted spacer fabrics are manufactured following ISO 9001:2015 certification, ensuring safety and quality.

What Are Some Uses for 3D Spacer Fabrics?

Because 3D spacer fabrics are highly customizable, they appeal to textile designers across multiple industries.

• Architectural: Spacer fabrics are soft, porous, and voluminous, making them ideal for sound absorption. Many buildings include insulation materials made from 3D spacer fabrics to control indoor noise.
• Automotive: 3D spacer fabrics are gaining popularity in automotive interiors because they provide sound insulation, thermal regulation, and impact resistance. Lightweight, breathable, and wear-resistant, 3D spacer fabrics are often used for ventilation and passenger comfort in car seats, seat belts, and door panels to increase the driver’s experience.
• Footwear and Apparel: From running shoe uppers to orthotic padding and other shoe insoles, 3D spacer fabrics help support feet and increase comfort. 3D spacer fabrics in intimate and athletic apparel promote higher breathability, temperature regulation, and drapability.
• Furniture: Several manufacturers opt for 3D spacer fabrics over foams in cushion pads, mattresses, and furniture due to the quick degradation and wastefulness associated with foams.
• Geotextiles and Filtration: 3D spacer fabrics are increasingly used in the geotextile and environmental protection sectors. Because they can be customized for a specific goal, spacers are increasingly used in erosion control, soil reinforcement, drainage, and filtration and separation applications.
• Medical: Due to their breathability, moisture management, and cushioning, spacer fabrics are ideal for pressure relief, comfort, and wound protection products in the medical field.
• Military and Tactical Apparel: High-performance spacer fabrics offer the breathability, cushioning, and durability required to withstand the demanding requirements of military and tactical apparel in physical training uniforms, flight suits, and MOLLE systems. Apex Mills is fully compliant with the Berry Amendment, which means our 3D spacer fabrics are made in the United States and can be used by the U.S. military.

Want to Know More? Spacer Fabric FAQs

Are 3D Spacer Fabrics Water Resistant?

3D spacer fabric faces can be designed for water resistance. While 3D fabrics are naturally porous, they can be coated with finishes to increase their moisture resistance. Water-resistant spacer fabrics are especially valuable in the medical industry, as health professionals use them to dress and protect wounds from getting wet.

Are 3D Spacer Fabrics Machine-Washable?

Spacer fabrics are machine-washable, so products made from 3D spacers can easily integrate into everyday life. 3D spacer fabrics can be easily machine-washed in cold water, depending on the product. However, it is always recommended to follow the washing instructions on the product itself.

Are 3D Spacer Fabrics Environmentally Friendly?

3D spacer fabrics are a viable replacement for foam in many industries. Foam degrades quickly and creates large amounts of waste. For a more sustainable option, 3D spacer fabrics can be made from organic yarns, biodegradable yarns, or recycled yarns. They can also be colored with low-eco-impact dyes.

Apex Mills designs, manufactures, tests, and approves all fabrics in our North Carolina, Virginia, and New York facilities. Trusted by Fortune 500 companies, law enforcement, and government agencies, we invite you to collaborate with us to address the needs of your specific application.

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