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As functional fabrics become increasingly segmented and specialized, sandwich mesh has become a focus of attention in many industries, especially in the fields of sports shoes, outdoor equipment, car seats, home mattresses, etc. It is known for its lightness, breathability, and strong support, and the realization of all these properties is inseparable from the most critical component of its structure - the middle layer support material, that is, monofilament yarn.

As the irreplaceable "skeleton" in sandwich mesh, the performance of monofilament directly determines the elasticity, morphological stability and service life of the entire fabric. With its excellent strength, resilience and durability, monofilament not only gives sandwich mesh a "visible three-dimensional sense", but also gives it "invisible functional performance" in use.

The structure and working mechanism of sandwich mesh: the design logic of the monofilament support layer

Sandwich mesh is a multi-layer composite structural material, and its basic structure is similar to a "sandwich", consisting of three parts:

• Surface layer: mainly for decoration, protection and contact, the material is often polyester or nylon knitted fabric
• Middle layer: the key support layer, usually woven into a three-dimensional structure by monofilament, is the core of determining support and breathability
• Base layer: used to enhance overall stability, composite or fit with other materials

Among them, the middle layer is the determining factor of the performance of sandwich mesh. This part of the material must have support, anti-compression, durable deformation, resilience and air circulation, and these requirements are highly consistent with the characteristics of monofilament yarn.

Common forms of monofilament support structure

• Z-shaped three-dimensional weaving: monofilament vertically connects the upper and lower layers, with the best resilience and support
• Wave weaving: enhances flexibility, suitable for comfort products such as mattress cushions
• X-interlaced weaving: enhances lateral support, used in pressure-resistant scenes such as soles or seat pads

Different structural forms and the thickness and material of monofilaments jointly determine the final performance of sandwich mesh.

Analysis of monofilament material properties: Why is it suitable for sandwich mesh?

The reason why monofilament is suitable for sandwich mesh is its unique physical and mechanical properties. These properties not only improve the use experience of the fabric itself, but also significantly extend the product life.

High strength and high stability

Monofilament is a continuous filament formed by polymer melt extrusion and stretching. It has a simple structure but high strength and low elongation. This feature ensures that the monofilament is not easily squeezed and deformed in the middle support layer of the sandwich mesh. Even under long-term use or repeated loads, the monofilament can stably maintain the support thickness of the fabric and provide lasting structural support for the product.

Excellent resilience

Resilience is a key indicator for measuring the comfort of sandwich mesh. Monofilaments made of high-performance materials such as TPEE, TPU, and PA can quickly return to their original shape after being subjected to pressure. This excellent resilience enables the monofilament to effectively achieve functions such as cushioning, shock absorption, and rebound in the sandwich mesh, thereby significantly improving the comfort of the product, especially in applications such as shoes, bags, and seats that require good support and shock absorption.

Excellent breathability, improved comfort

Unlike traditional foam materials, the monofilament support layer has an air structure inside, which allows airflow to penetrate freely. This open structure is not easy to accumulate heat or moisture, which significantly improves the comfort when wearing or using. Whether in shoes, backpacks or mattresses, good breathability can effectively prevent stuffiness and humidity, bringing a more refreshing use experience.

Environmental protection and durability

Polymer monofilament raw materials usually have excellent wear resistance, chemical resistance and hydrolysis resistance. These characteristics ensure that the sandwich mesh made of monofilament can withstand the test of long-term use and repeated washing, thereby greatly extending the service life of the product. At the same time, the monofilament material also meets the strict environmental protection standards such as RoHS, REACH, OEKO-TEX, which makes it not only durable, but also more environmentally friendly and sustainable, meeting the needs of modern consumers for green products.

Common monofilament material comparison table

Analysis of the production process of monofilament sandwich mesh

The application of monofilament in sandwich mesh is not a simple embedding, but requires precise control of each process to ensure a firm structure and consistent performance. The following is the basic process:

Monofilament manufacturing

• Raw materials: PA, PET, TPEE, TPU, etc.
• Process: melt extrusion → stretching and shaping → cooling and winding
• Requirements: Wire diameter accuracy ±0.01mm, ensuring tension stability and weavability

Weaving link

• The monofilament is introduced into the weaving equipment and woven synchronously with the upper and lower layers of yarn.
• The support layer weaving structure is determined by the purpose, usually Z-shaped three-dimensional weaving or wave support.

Heat setting and tension treatment

• The fabric is heat treated (within the range of 180°C~220°C) to fix the structure and improve stability.
• Tension needs to be controlled during the setting process to avoid support collapse or fabric curling.

Post-processing and testing

• The testing items include thickness tolerance, elastic rebound rate, peel strength, air permeability, etc.
• Use segmented sampling and online testing systems to improve product consistency.

Monofee has complete monofilament production and weaving supporting equipment to ensure that each batch of monofilament mesh is in a controllable state from raw materials to delivery, especially suitable for customers' personalized customization needs.

Are you looking for a suitable Monofilament Yarn manufacturer? You've come to the right place. We are committed to providing our customers with high-quality products and the best value. Your satisfaction is our driving force. Send an email to janekwok@xll-group.com Today, our supplier will be happy to serve you.

Industry application analysis of monofilament sandwich mesh

Sports shoe midsole and upper structure

The monofilament structure provides strong support, improves the compression resistance and rebound performance of the sole, and can effectively reduce the weight of the shoe body. It is widely used in running shoes, basketball shoes, functional shoes and other fields.

Backpack shoulder straps and carrying system

Traditional EVA foam is easy to deform and stuffy. The sandwich mesh with a monofilament support layer can maintain good ventilation and reduce the burden. It is an ideal choice for outdoor mountaineering bags and tactical backpacks.

Medical and home cushions

The elastic support structure of the sandwich mesh provides uniform support for the body, which is especially suitable for patient mattresses, seat cushions, anti-bedsore products and other uses.

Car seats and interiors

As a foam alternative, the monofilament support layer mesh has strong pressure resistance, does not absorb water, and does not collapse. It is more suitable for long-term riding scenes and is in line with the environmental protection trend.

Baby and pet products

The sandwich mesh made of TPU and TPEE monofilaments is non-toxic, easy to clean, and has good elasticity. It is suitable for products with high safety requirements such as baby mattresses, pet mats, and children's protective gear.

How to choose high-quality monofilament materials and suppliers?

Choosing the right monofilament materials and production partners is the key to ensuring product quality and performance. Here are a few suggestions:

Material selection suggestions

• Clear use: PA6 or TPEE is recommended for shoe materials; TPU or TPEE is recommended for medical use.
• Focus on performance indicators: tensile strength, elastic recovery rate, and thermal stability are key parameters.
• Environmental compliance: Whether it has passed environmental protection tests such as OEKO-TEX is an important reference for export products.

How to choose a high-quality monofilament supplier

Choosing the right supplier is as important as choosing the material itself. A good supplier can provide stable quality, reliable delivery and considerate service.

• Evaluate customization capabilities: The ideal supplier should have strong customization capabilities and be able to adjust according to your specific needs (such as monofilament diameter, stiffness, color, etc.). This ensures that the material can perfectly adapt to your production equipment and weaving process, thereby optimizing production efficiency and product quality.
• Investigate supply stability and scale: It is crucial to choose a supplier with high annual production capacity and stable supply record. This means that they can meet your large-volume order needs and support global delivery to ensure that your production line will not be interrupted due to material supply problems.
• Pay attention to service and technical support: High-quality suppliers not only sell products, but also provide comprehensive services and support.Providing professional application advice and supporting technical docking can ensure that the material is best used in your production process and solve possible technical problems.
• Check industry experience and professional fields: Understand in which industry fields the supplier has expertise, such as footwear, home furnishings, automobiles or medical. If their experience closely matches your application area, it usually means they have a deeper understanding of the needs and challenges of that field.