German textile machinery manufacturer KARL MAYER has launched a new double needle bar raschel machine designed to expand design possibilities for spacer fabrics used in athletic footwear, as demand grows for lightweight, breathable and visually distinctive shoe uppers.
The company said on Tuesday the new RDJ 7/3 features three jacquard bars, compared with conventional configurations, allowing manufacturers to create more complex mesh structures, multi-color patterns and functional zones within a single fabric.
Spacer fabrics are widely used in sports and casual footwear because they combine cushioning, breathability and durability while offering manufacturers greater flexibility in product design.
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According to KARL MAYER, the RDJ 7/3 enables nearly perfectly round mesh openings, larger ventilation holes and more intricate jacquard patterns. The machine can also produce two-color effects and accommodate up to six different yarn colors, allowing footwear brands to develop a broader range of visual designs.
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The machine also introduces three-dimensional surface effects by incorporating an additional yarn into the pile area through a third jacquard bar. Depending on the yarn selected, manufacturers can create localized stretch, shrinkage or embossed structures, resulting in multi-layer fabric designs intended to improve both aesthetics and functionality.
KARL MAYER said the RDJ 7/3 is equipped with eight guide bars for pile formation, providing greater structural flexibility for spacer fabric production.
Beyond footwear, the company said the machine can also produce spacer fabrics for mattress covers and other applications requiring breathable materials with textured surfaces.
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The RDJ 7/3 is available with a working width of 138 inches and an E24 gauge. Its trick plate distance can be adjusted between 2 mm and 5 mm, allowing manufacturers to produce fabrics of varying thicknesses for different end uses.
The machine also features a wireless jacquard system designed to simplify operation, improve visibility during production and reduce labor requirements. KARL MAYER said the combination of high production speed, fabric quality and design flexibility makes the RDJ 7/3 suitable for large-scale manufacturing.