Methods of Manufacturing

Woven Felt

• Wool or a blend of wool and other yarn is woven into a cloth then felted using steam and pressure to make the fibers interlock.
• Very durable and resilient fabric.
• Cut parts may fray and have loose fibers.
• Maximum thickness 1/2".
• Typical uses include:
  • Printing (Etching) Blankets
  • Musical Instruments
  • Door Seals

Pressed Felt

• Oldest form of fabric known to man, predates weaving and knitting.
• Wool fibers or a blend of wool and other fibers are pressed together with steam and pressure to allow the fibers to naturally interlock.
• This felting process produces a fabric that is slightly less durable than the woven felt but is less expensive and can be made thicker.
• Parts will not fray and loose fibers are minimal.
• Can achieve very high densities
• Maximum thickness 3".
• Typical uses include:
  • Filters
  • Wicks
  • Gaskets
  • Wipers

Needled Felt

• Synthetic fibers or a blend of wool and synthetic fibers are interlocked using machines with thousands of needles moving in an up/down motion to mechanically interlock the fibers.
• Wool blends are less expensive than pressed or woven blends but tend to exhibit a bevel at the edge of cut parts.
• Cut parts do not fray and loose fibers are minimal.
• Maximum thickness 1-1/2".
• Typical uses include:
  • Craft Felts
  • Inexpensive substitute for Pressed Felts
  • Cushioning
  • Felt bottoms for lamps

Composition

100% Wool Fiber Felt

• Fibers come from sheep.
• All natural and has excellent wicking and durability properties.
• Is most often pressed or woven.
• Can be needled but usually has binders added to help hold fibers together.
• High quality and density
• Typical uses include:
  • Bearing seals
  • Polishing Pads
  • Wipers
  • Lubricators

Blends of Wool and other fibers

• Varying ratios of nylon, polyester, rayon, polypropylene, or cotton are mixed with wool to meet published specifications or control performance and cost.
• Can be pressed, woven or needled.
• Low density and cost
• Typical uses include:
  • Packing
  • Filters

100% Synthetic Fiber Felt

• Polyester, polypropylene, Teflon, Nomex, Rayon, and Kevlar fibers are needled or woven to form fabrics which perform to the fibers specifications.
• Cost is dependant on the fiber cost.
• Materials can be die cut with no fraying and minimal loose fibers.
• Widest range of applications from very low tech and general to high tech and specific
• Typical uses include:
  • Filters
  • Weather Stripping
  • Straps
  • Packing and Cushioning

Form

Felt Rolls

• Felts with thicknesses of 1/32" to 1" and densities up to 18 lbs/sq.yd. come in roll form.
• The length of the roll is dependant on the thickness of the felt and varies from approximately 8 to 300 yards.
• The width of the roll is between 54" and 84".

Felt Sheets

• Felt with densities greater than 18 lbs/sq.yd. are usually made in 36" x 36" sheets and can be made up to 3" thick.
• These felts can be custom made in larger sheets if needed.