Seamless garment: Needle selection techniques
and applications
by P. Kanakaraj and R.Ramachandran, PSG College of Technology.
Knitting is the process of intermeshing loops of yarns thereby forming fabric and is classified as warp and weft knitting. Weft knitting
can be further classified into Circular and Flat knitting. Flat knitting machines have greater versatility in loop structure combinations
and designing. This is because of their machine cams structure and their ability to stitch one or both beds easily. As machines
improve with the evolutionary technology, higher productivity, increased efficiency, lower material costs and better consistency and
quality are attained. With industrial progress and subsequent development in mechatronics technology, the advancements in gar-
ment manufacturing have evolved from cut & sew to complete garment knitting, which produces one entire garment without
sewing or linking process. This technology was introduced in 1995 at ITMA (International Textile Machinery Association) .V-Bed
knitting process has more flexible needle selection capability and more design possibilities through computerized system (DSCS –
Digital Stitch Control System) compared to warp knitting process. Eventually, the seamless garment process puts less stress on the
environment by minimizing waste disposal.
Evolution of knitting production
Cut and sew process
Panel knitting involves knitting an entire panel of fabric to
accommodate the front body, back body and sleeves. This con-
ventional method requires the patterns for the bodies to be cut
out from the fabric and sewn together involving several post-knit
processes. With this process, up to 40% of the original fabric may
go as waste or cut-loss. Fig. 3: Integral Knitting
Apparel & Knitwear
Integral knitting
The integral knitting entails the use of shaping technology to
knit pattern-shaped pieces. It improves upon shaping by knitting-
in or integrating trimmings, pockets and other accessories, such as
buttonholes to avoid sewing together these items. Great savings
can be obtained in post-knit processing. The quality and consis-
tency are vastly improved.
Seamless Garment
knitting
Fig. 1: Cut and sew process. In knit-wear produc-
tion, complete garment
Shaping can be referred as
“whole garment” or
Full fashioning allows the front and back bodies and sleeves “complete garment”.
to be knitted according to specific pattern shapes for each piece. The garments can be
Each pattern is shaped using only the amount of yarn necessary produced either in circu- Fig. 4: Seamless garment.
to knit that piece, with added seam allowances. So cut-loss is lar knitting machines or
eliminated. Trimmings and pockets still must be knit separately. flat (V-Bed) knitting machines. Production is by using several dif-
Post-knit linking and sewing are required to complete the cardi- ferent feeders with minimal or no cutting and sewing processes.
gan. The type of production varies in both circular and flat knitting.
Fig. 5a: Complete garment knitting Fig. 5b: Complete garment
until Underarm point. knitting after Underarm point.
Fig. 2 Shaping. (Shima Seiki’s) (Shima Seiki’s)
44 PTJ January 2010
In circular knitting, it creates a single tubular type of garment
and then tubes are joined together on the machine. This ensures
minimized cutting and seam joining on one body tube and two
sleeve tubes as well as the finished edges. Consequently, seamless
knitting on circular machines is not true seamless knitting. Flat V-
bed knitting creates complete garments, which do not require any
kind of cutting or sewing process. Here three separate tubular
parts formed by knitting is shown in Fig.4, one wider tube for the
body part and two narrower tubes for the sleeve parts by alter-
nate knitting of front and back beds. Moreover, various structures
like plain jersey, rib and purl can be created within the seamless
garment at the same time.
Fig. 7b: DSCS representation for the loop transference.
Feeder 2 knits the main body part also knitting together the three
tubes into one (Fig.5b). However, in order to make loop transfer-
ence for performing the shaping or design structures loops should
be formed by selecting alternate needles.
Shima Seiki has introduced 12 stitch techniques for the pro-
duction of whole garment. For patterning in weft knitting, the
Apparel & Knitwear
selection of needles is very important which can be achieved in
Fig. 6: Stitches from Shima Seiki machine. any one of the following method.
(i) Direct needle control.
(ii) Indirect needle control and electronic control.
The flat knitting machine, knits and transfers loops between In case of direct needle control, the control is carried out by
the front and back needle beds with different yarn carriers; one cam parts or pattern wheels, which directly acts on pattern knit-
body tube (feeder 2) and two sleeves tubes (feeder 1 and 3) as ting butts. In indirect needle control, one or several control
shown in Fig.5a. At the underarm point, the two carriers feeder 1 sinkers/pins are arranged after the needle in the same groove of
and 3 knitting sleeve parts are taken out from the knitting zone. the needle carrier. Pattern drums battery selectors or sliders are
Feeder 2 knits the main body part also knitting together the three such examples. Needle selection through film tapes, control mag-
tubes into one (Fig.5b). However, in order to make loop transfer- nets etc. comes under electronic control category.
ence for performing the shaping or design structures loops should
be formed by selecting alternate needles. In complete garment production, the CAD system interlinked
with DSCS (Digital Stitch Control System) is a totally integrated
The flat knitting machine, knits and transfers loops between knit production system that allows all phases including planning,
the front and back needle beds with different yarn carriers; one designing, evaluation and production. CAD patterning is more
body tube (feeder 2) and two sleeves tubes (feeder 1 and 3) as complicated than that of the fully fashioned knitting, because of
shown in Fig.5a. At the underarm point, the two carriers feeder 1 its alternate needle selection. Fig. 7a & Fig. 7b shows the loop
and 3 knitting sleeve parts are taken out from the knitting zone. transference in complete garment knitting at under arm point. For
this, atleast two loops (even number of loops only) are transferred
in a right or a left direction due to alternate needle selection.
Applications
Seamless garments are preferred for their comfortability, for-
giving, non-binding, non-restrictive characteristics and tend to
show fewer lines under clothes. In addition, seamless apparel will
have no failures on waistband and side seam.
Manufacture fibers such as nylon with atmospheric garment
dyeing offer greater durability. Fig. 8 shows a multi-color dyed
complete garment created on computerized knitting machine.
Seamless technology has emerged into areas such as fashion,
upholstery, industrial, automotive and medical textiles apart from
apparel.
Upholstery
Three-dimensional seamless seat office chairs done using
sophisticated CAD system. The fabrics possess stretch character-
Fig. 7a: Needle representation for the loop transference. istics to follow contours of seat.
PTJ January 2010 45
ports, medical compression stockings and more. With the incor-
poration of high performance fibers and additional sensors or
electronics, unique combination of fibers which are designed for
comfort and purpose is achieved. Specialized aesthetics, wellness
application and massaging properties are such benefits have
improved recovery. Shape wear offers support for pre/post sur-
gery. Certain medical procedures can be even delayed or/and
avoided.
Intimate apparel
Intimate apparel produced on seamless machines gives seam-
free, easy-care, silky-smooth, comfort and fit and gives a feel sim-
ilar to one’s second skin. This is suitable for today’s lightweight
Fig. 9: Seamless glove. apparel. In a bid to speed-up the development of the circular
seamless innerwear market, Santoni has introduced a new single
jersey machines for the production of under wear, swim wear and
sanitary garments.
Fig. 8: Multi-color dyed complete
garment created on computerized
Conclusion
knitting machine. .
New advancements coming from fiber producers and yarn
Engineered design related to spinners will continue to provide innovation from the supplier
knitwear performance in pro- side. Seamless garment knitting creates one entire garment by
ductivity involving various knit
using several different carriers eliminating the need for additional
structures.
cut and sew operations. By utilizing alternate needle selection one
Apparel & Knitwear
The recent models of com- can also knit various design structures apart from shaped knitting.
puterized knitting machines pro- Complete garment knitting provides major benefits for the
vide technically as well as market as well as for technical production. It offers savings in
aesthetically advanced design terms of production times and cost, and it minimizes yarn con-
possibilities to create garments. Fig. 10: Medical seamless socks.
sumption.
This recent development in
upholstery manufacturing using In addition, seamless garment knitting provides more consis-
knits enhances appearance, tent and homogeneous product quality, which gives lightness and
better seat trimming while elim- comfort in the garments. It also offers more creative knit possibil-
inating ridges. ities for knit designers. Three-dimensional seamless knitting with
its diverse capabilities can be applied to numerous products such
Automotive and industrial textiles as apparel, fashion, upholstery, Automotive, aerospace, medical
textiles, etc. Seamless knitting is forecasted to continue growing
Automotive seat covers obtained by usage of predictive com- and could be one of the largest next generation knitting technolo-
puter models with the possibility to alter the knitted tube size. It
gies.
adds on quality, provides ergonomic seat design and 25% time
saving. References
KEVLAR offers seamless filament-knit gloves and apparel
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sion business sectors which require high levels of safety in addi- Issue-3, spring -2005
tion to contaminant-free cleanliness.
[2] Ajgaonkar, D.B.: Knitting technology, Universal publishing,
Sports Textiles 1998
[3] Shishoo, R.: Textiles in Sport, the Textile Institute, 2005
Sports apparel demand high performing garments to enhance
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engineered fit, micro massaging features and performance inno- [5] Wonseok Choi.: The development of specialized knitted
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These styles are developed for fitness and first layer. The North Carolina State University, Doctor of philosophy,
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interest in seamless garment construction. A diverse range of
products such as hand gloves, hats, socks, are some of the obvi- [6] http://www.shimaseiki.co.jp
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[8] http://www.makemeheal.com
Medical textiles
[9] http://www.travelsocks.com.au
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been a boon. Applications include bandages, orthopedic sup- [11] http://www.kevlar.com.
46 PTJ January 2010
