Design optimisation of thermal properties, moisture management and physical characteristics in four-layer woven fabrics

Multi-layered 3D fabric has been the subject of research interest due to its ability to reinforce, absorb energy and provide different degrees of flexibility to provide specific properties. This study introduces a systematic approach for designing four-layer woven fabrics by using different yarn fibre contents and fabric structures. The layers comprise satin, 2/2 twill, 3/1 twill and plain weave structures made of bamboo, Coolmax, cotton, and polyester yarns in different combinations. The layers are connected by adding interlocking weaves at certain stitch points. Nine samples were fabricated and their physical, thermal, moisture management, and mechanical properties were examined. The results showed that integrating Coolmax in more layers, such as the sample with three layers of Coolmax, enhances heat transfer(with the lowest thermal resistance value of k = 0.0036 W/cm·°C)with good moisture management (with an Optical Moisture Management Capacity (OMMC) of 3.5). Using layers with different structures increases air resistance reaching 0.6 kPa·s/m. Using the same structure for more than one layer (e.g. four layers made of irregular satin) leads to increased surface roughness (surface roughness (SMD) = 13.965) due to increased friction (with the highest mean frictional coefficient (MMD) value of 0.31). The use of one type of structure increases fabric rigidity and density, whereas layers of different structures with interlacing points offer fabric suppleness and compressibility. The study outcomes contribute to advanced textile engineering and provide solid groundwork for future applications that require performance enhancement.