What is Super-large Warp-knitted Air Spacer Fabric

Super-large air-mesh warp-knitted spacer fabric is a new type of three-dimensional spacer fabric with two surfaces connected by spacer yarns and a large distance between them. It is also called warp-knitted 3D structure fabric or brushed fabric.

The thickness of super-large warp-knitted spacer fabrics is usually 100-300 mm (the spacer yarn is stretched), and there are very few fabrics whose thickness can reach more than 650mm.

Super-large warp-knitted spacer fabrics of different thicknesses have different requirements for raw material types and properties, warp knitting machines processing technology, etc. 

The super-large space determines its high and unique application value, making it a kind of versatile, high-performance fabric.

The Structure of Super-large Warp-knitted Air Spacer

The super-large warp-knitted spacer fabric is knitted from two surface yarns and one spacer yarn in the middle. The fabric is divided into three layers, namely the upper surface layer, the spacer layer, and the inner surface layer.

The spacer yarn runs between the two surface layers according to certain rules, forming a spacer layer with a certain thickness and spatial structure between the two surface layers of the fabric.

Features of the Super-large Warp-knitted Spacer Fabrics

• The Thickness of the air-spacer fabrics

  The spacing distance of super-large warp-knitted spacer fabric is very large, usually about 100-300 mm, and the distance can also be produced according to the requirements of different structural properties. At present, the common fabric thicknesses are 70, 80, 100, 150, 200, 250, 300mm, etc., sometimes even as high as 650mm. The thickness of the surface layer of the fabric is about 1-2 mm, and it is usually 2.1-3.0 mm after coating.

• High-strength Filaments used in Warp-knitted Large Spacer Fabrics

  The arrangement density of spacer filaments in the fabric is small, and high-strength filaments are used. In general, if the density of spacer yarn is too high, the compressed thickness of the product will increase, making it difficult to store, and it will also cause waste of excess spacer yarn. If the spacer yarn density is too small, the strength of the spacer layer cannot be guaranteed, so the spacer yarn density should be designed according to the specific application of the fabric.

• Basic Lapping Movement of the Warp-knitted Spacer Fabrics

  The surface structure of the fabric generally adopts 1 and 1 Lapping Movement to meet the needs of the coating. Ordinary warp-knitted spacer fabrics generally use high-modulus polyester monofilaments or polypropylene monofilaments to avoid bending and lodging of the spacer yarns. However, the warp-knitted spacer fabric with a super-large distance has a large length, low rigidity, and low arrangement density. The fabric cannot rely solely on the support of the spacer to achieve compressive performance, so it must be coated with a surface coating and filled before it can be improved. exert its performance.

Super-large Warp-knitted Spacer Fabrics Manufacturing Technique

• Yarn Material For the Super-large Warp-knitted Spacer Fabrics

  The spacer yarns used in super-large distance warp-knitted spacer fabrics are mostly multi-filaments, and chemical fiber materials with high strength and low elasticity are mostly used, such as 150-300D polyester multi-filaments. Following production data from the AZ2885 model double-needle bar raschel warp knitting machine:

• Warp Knitting Structure Notation 

  The threading of spacer yarns in super-large distance warp-knitted spacer fabrics is relatively sparse. In the warp knitting process of spacer yarns, the Miss-lapping Technique can be properly added to achieve the required spacer yarn density. For example, the surface structure adopts the process of Pillar Stitch and Lay-in combination.

• Finishing Process

  The common coating material in the textile field is polyvinyl chloride (PVC), which makes the fabric waterproof and well-sealed, and can also enhance the abrasion resistance. In addition, a flame retardant is also added to the coating material to give it a flame-retardant function.

Applications of the Large-distance Warp-knitted Spacer Fabrics

• Sporting Goods

  Warp-knitted spacer fabric inflatable cushions with super large gauge are also called inflatable brushed air cushions, which can be used in sports goods, such as gymnastics, martial arts training air cushions, fitness mats, yoga mats, etc. The inflatable cushion can reduce the collision between the athlete and the ground during training, absorb the excessive impact force of the human body, and play the role of cushioning and protection.

• Water Inflatable Surf Boats

  Boats and water skis made of warp-knitted spacer fabrics with super-large air spacers are light in weight, easy to inflate, and easy to store and carry after folding. The fabric can also be used as a seat on an inflatable boat.

  The lightweight seat will not add a weight burden to the inflatable boat, and the human body will not have local heating when sitting on this inflatable seat like foam products. Nowadays, more products such as inflatable fishing boats and surfboards are made from the warp-knitted air spacer fabrics. 

• Mattress Mat Home Furnishings

  The inflatable brushed air mattress can be used as an air cushion and bedroom mattress. This type of mattress can adjust the softness and hardness of the mattress by adjusting the internal air pressure, that is, to choose the appropriate softness and comfort according to personal preferences.

  This type of mattress can also be used as a camping tent pad, which is easy to store and carry, and the coating on the bottom of the fabric also has good moisture-proof as well as breathable effects. Jacquard air-mesh spacer fabric, which is produced by RDJ5/1 model warp knitting machine is another warp-knitted spacer fabric used as mattress mats. 

Frequently Asked Questions (FAQ)

Q1: What is the typical thickness range for super-large warp-knitted spacer fabric?

Standard production thicknesses range between 100 mm and 300 mm (e.g., 70, 80, 100, 150, 200, 250, 300 mm). Advanced machinery and specialized finishing can achieve maximum thicknesses up to 650 mm.

Q2: Why are multifilaments preferred over monofilaments for super-large spacer yarns?

Because super-large spacer distances (over 100 mm) result in longer yarn spans, monofilaments tend to buckle easily under compression without providing high density. High-tenacity multifilament yarns (e.g., 150D–300D FDY) combined with airtight surface coatings deliver optimal tensile strength, airtightness, and flexible folding performance.

Q3: Which A-ZEN machine models produce super-large and 3D spacer fabrics?

The AZ2885 double-needle bar raschel warp knitting machine is specifically designed for high-thickness air spacer structures, while models like the RDJ5/1 specialize in jacquard air-mesh mattress spacer fabrics.

Q4: How does PVC coating enhance the performance of super-large spacer fabrics?

The PVC coating seals the outer surface layers of the fabric, ensuring 100% airtightness and waterproof capability for inflatable air mats and boats. Additionally, flame retardants can be added to the coating to meet international safety standards.

Q5: Why is warp-knitted air spacer fabric superior to traditional foam for inflatable mattresses and mats?

Unlike traditional foam, warp-knitted air spacer fabric allows precise air pressure adjustments for customizable firmness. It offers significantly higher tensile strength, localized pressure relief, rapid moisture dissipation, and compact, foldable storage for transport.

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