Effect of surface layer design on the physical properties of weft-knitted spacer fabrics for wound dressing applications

Ideal wound dressings typically incorporate key features, including moisture management, air permeability, temperature control, and mechanical protection to enhance the healing process, minimize infection risk, and promote patient comfort. In this research, six weft-knitted spacer fabrics with varying surface layer designs comprising combinations of knit and miss stitches were developed. Their physical properties were then analyzed and compared with those of two commercially available wound dressings. Results indicated that incorporating miss stitches and increasing their proportion in the surface layer led to notable reductions in performance: water vapor permeability (WVP) dropped by 27.2%, compression resistance by 55.7%, thermal conductivity by 71%, and absorbency by 22%. Additionally, the commercial wound dressings showed 49.3% lower WVP, 93.5% lower air permeability, and 19.3% lower compressibility, but exhibited 38% greater absorbency than the spacer fabrics. Their thermal conductivity was 57% higher than some spacer samples, yet 52.6% lower than others. Based on these findings, the use of miss stitches in the surface layers of spacer fabrics is not recommended for wound dressing applications.