Spherically curved woven fabrics: geometrical calculation methods and weave pattern development

The demand for woven spherical shapes, particularly in applications such as fiber-reinforced plastic (FRP), is increasing. However, the production of woven two-dimensional fabrics in three-dimensional (3D) shapes using conventional weaving machines faces technical limitations. As a result, draping and cutting processes are commonly employed to transform flat woven fabrics into 3D shapes, leading to challenges such as structural distortions, thread interruptions, layer overlaps, and high cutting losses. To address these issues, this research introduces a novel weaving technology that enables the creation of spherically curved woven fabrics utilizing conventional weaving machines. Using the developed technology it is possible to fabricate double curved fabrics without the cutting and usual draping processes that can be implemented to reinforce FRP components. The study presents mathematical models capable of calculating the required 3D surfaces for such fabrics. By adopting this technology, the need for draping and cutting processes can be eliminated, leading to improved quality and structural integrity of the final product.