Needle-punched fabric refers to a non-woven fabric that is produced without warp and weft threads, using the needle-punching method. In this process, granules are melted and sprayed onto a moving belt, then shaped into fabric with the help of air pressure and fine needles—thus the term “needle-punched fabric.” The mechanism is similar to felt production and involves spraying and compression. This mesh-like, perforated fabric is made of synthetic polypropylene fibers and granules, and due to its lightweight and elasticity, it has applications in various industries.
Features of Needle-Punched Fabrics
Mesh Structure with Small Holes
This fabric has fine micro-perforations (~10 microns) that allow easy airflow.
Lightweight and Thin
Needle-punched fabrics are low in volume and very light.
Durability and Strength
These fabrics resist stretching and abrasion.
Permeability to Air and Water
They allow air and water to pass through easily, making them cooling fabrics. They can be manufactured in both absorbent and water-repellent forms.
Easy to Sew
Due to their thinness, needle-punched fabrics can be easily sewn with overlock machines, and ultrasonic sealing is also very simple.
Highly Recyclable
They are environmentally friendly and can be recycled easily. Their flexibility allows for production in narrow or wide widths, and enhancements like antibacterial, UV-resistant, or reinforced features can be added.
Economic Efficiency
Being lightweight, one kilogram of needle-punched fabric covers a large area, making them cost-effective.
Lint-Free Property
They do not shed lint and do not attract dust.
High Dye Affinity
These fabrics absorb dye easily during the coloring process.
Applications of Needle-Punched Fabrics in Various Industries
Sports Industry
Used in sportswear and warm-ups due to their two-way stretch.
Apparel Industry:
Used as lining in clothes, bags, suit and coat covers, and drawer organizers.
Medical Industry
Used in three-layer surgical masks, child masks, disposable sheets (like MRI room bed covers), gowns, surgical caps, and single-use visitor attire in hospitals.
Advertising Bag Industry
Popular for making fabric promotional bags.
Furniture Industry
Used as linings in furniture manufacturing.
Bedding Industry
Used for bedspreads and pillow covers.
Agriculture
Used in producing agricultural covers, weed control mulch, fruit protection bags, and anti-evaporation wraps.
Packaging Industry
Used for packaging fertilizers, coarse grains, spices, electrical appliance parts, faucets, sinks, ovens, stoves, and hoods.
Automotive and Filtration Industries
Used in vacuum cleaner filters and automotive interior linings.
Classification of Needle-Punched Fabrics
1 – Based on grammage, ranging from 15 to 200 gsm for various industrial uses.
2 – Based on number of layers:
– Single-layer: simplest, soft, and lightweight
– Double-layer: stronger and softer
– Triple-layer: high durability and common in medical use
– Four-layer: includes one melt-blown layer and three fabric layers with excellent filtration (e.g., masks)
3 – Composite and laminated types: combined with other layers or water-resistant foam for virus and water resistance
4 – Based on added features: expands their usability in various conditions
5 – Based on target markets
6 – Based on available colors and printing methods like silk screen and flexo
How Printing Works on Needle-Punched Fabrics
- The surface is grainy due to irregular fibers and rough texture.
- Dye absorption is low, so colors may appear dull.
- Ink may spread in the fibers due to the fabric’s weave.
- Details may not appear sharp.
Common Printing Methods:
- Silk screen printing: great for high-volume or single/three-color prints; gold ink can be added.
- Thermal printing: feasible if the fabric is heat-resistant.
Where Printed Needle-Punched Fabrics Are Used
- For promotional tote bags with or without gussets and die-cut handles
- In covers for folders, button folders, and packaging
Sales of Needle-Punched Fabrics
Yazd Laie is the largest producer of needle-punched fabrics in the country, highly active in producing both fabrics and their derivatives.
Sales are conducted in cash directly from the factory or by contacting sales experts through social media. For verified, creditworthy customers with high bank account activity, purchases can also be made via checks.