Methods of Manufacturing


Forms:-
Woven Felt
Wool or a blend of wool and other yarn is woven into a cloth then felted using steam and pressure to make the fibers interlock.
Very durable and resilient fabric.
Cut parts may fray and have loose fibers.
Maximum thickness 1/2".
Typical uses include:
Printing (Etching) Blankets
Musical Instruments
Door Seals

Pressed Felt
Oldest form of fabric known to man, predates weaving and knitting.
Wool fibers or a blend of wool and other fibers are pressed together with steam and pressure to allow the fibers to naturally interlock.
This felting process produces a fabric that is slightly less durable than the woven felt but is less expensive and can be made thicker.
Parts will not fray and loose fibers are minimal.
Can achieve very high densities
Maximum thickness 3".
Typical uses include:
Filters
Wicks
Gaskets
Wipers

Needled Felt
Synthetic fibers or a blend of wool and synthetic fibers are interlocked using machines with thousands of needles moving in an up/down motion to mechanically interlock the fibers.
Wool blends are less expensive than pressed or woven blends but tend to exhibit a bevel at the edge of cut parts.
Cut parts do not fray and loose fibers are minimal.
Maximum thickness 1-1/2".
Typical uses include:
Craft Felts
Inexpensive substitute for Pressed Felts
Cushioning
Felt bottoms for lamps

Felt Rolls
Felts with thicknesses of 1/32" to 1" and densities up to 18 lbs/sq.yd. come in roll form.
The length of the roll is dependant on the thickness of the felt and varies from approximately 8 to 300 yards.
The width of the roll is between 54" and 84".

Felt Sheets
Felt with densities greater than 18 lbs/sq.yd. are usually made in 36" x 36" sheets and can be made up to 3" thick.
These felts can be custom made in larger sheets if needed.



Composition:-
100% Wool Fiber Felt
Fibers come from sheep.
All natural and has excellent wicking and durability properties.
Is most often pressed or woven.
Can be needled but usually has binders added to help hold fibers together.
High quality and density
Typical uses include:
Bearing seals
Polishing Pads
Wipers
Lubricators

Blends of Wool and other fibers
Varying ratios of nylon, polyester, rayon, polypropylene, or cotton are mixed with wool to meet published specifications or control performance and cost.
Can be pressed, woven or needled.
Low density and cost
Typical uses include:
Packing
Filters

100% Synthetic Fiber Felt
Polyester, polypropylene, Teflon, Nomex, Rayon, and Kevlar fibers are needled or woven to form fabrics which perform to the fibers specifications.
Cost is dependant on the fiber cost.
Materials can be die cut with no fraying and minimal loose fibers.
Widest range of applications from very low tech and general to high tech and specific
Typical uses include:
Filters
Weather Stripping
Straps
Packing and Cushioning