Review article

Textile Research Journal

0(00) 1–16

Development in the multiaxis ! The Author(s) 2015

Reprints and permissions:
sagepub.co.uk/journalsPermissions.nav
3D weaving technology DOI: 10.1177/0040517515612365
trj.sagepub.com

Ahmad Rashed Labanieh, Xavier Legrand, Vladan Koncar and

Damien Soulat

Abstract
Multiaxis 3D weaving technology allows insertion of in-plane fibres reinforcements, designated as bias yarns, oriented in
directions other than 0 and 90 in the woven preform, unlike in the case of conventional weaving technology. By
different existing weaving advanced techniques, two opposite bias yarn layers are formed, with no possibility to separate
them by in-plane yarn layer oriented in 0 to reduce inter-layer angle. That could be the cause of weak interlaminar shear
resistance in the final composite structure. In this present paper, a novel development is proposed to solve the issues
related to the guide block technique, which is used to position the bias yarns in the weaving zone on the weaving loom.
Thus, in order to enable insertion of in-plane yarns layer oriented in 0 between the two opposite successive bias yarn
layers (y ). Furthermore, the proposed technique is upgraded to control the width of produced preform on the loom.
The proposed approach has reduced degradations of the in-plane warp and bias yarns during a weaving process caused by
the friction with reed blades. Geometrical characterization of manufactured preform, using the developed multiaxis 3D
weaving loom prototype, has been carried out to observe the yarn geometry inside the impregnated preform. Similarly,
the geometrical properties of the impregnated preform are compared with those of multiaxis 3D woven preforms
produced by the tube carrier weaving technique and the tube rapier weaving technique.

Keywords
3D fibre reinforcement, multiaxis 3D weaving, geometrical characterization

The three-dimensional (3D) weaving technology is
developed in response to the poor delamination resist-
ance of laminated composite structures by insertion of
through-the-thickness fibre reinforcements.1-4 Yet, this
technology3-7 is limited relative to the possibility of
insertion of in-plane fibre reinforcement in a direction
y other than 0 and 90 , denoted bias. That results in
reduction of the in-plane off-axis tensile properties and
the in-plane shear resistance of the 3D woven compos-
ite.8-11 Therefore, multiaxis weaving technology has
been developed to allow this insertion.
Compared with the conventional 3D weaving pro-
cess, guaranteeing a proper displacement of the bias
yarns (oriented in  y ) in the weaving zone during
weaving process is the essential requirement in the tech-
nology. Several innovated technologies for multiaxis
2D12–17 and 3D9,18-25 weaving process were published
in the literature. Among these technologies, the tube
carrier weaving technique and tube rapier weaving
technique presented by Bilisik and Mohamed21-25
could be highlighted regarding the possibility of fabri-
cation of thick multiaxis 3D woven preforms with high
fibre volume fraction.
In the tube rapier weaving technique,22 both warp
and bias yarns are passed through tube rapiers. These
tubes are arranged in a matrix corresponding to the
demanded shape for the preform cross-section.
Needles passing between the tube rapiers of the bias
and warp yarns insert filler and binder yarns. That
reduces the incurred damage to the warp and bias
yarns, which is met in other technologies, by insertion
ENSAIT, Lille 1 University - Science and Technology, France
Corresponding author:
Ahmad Rashed Labanieh, GEMTEX Laboratory, ENSAIT, Lille 1
University - Science and Technology, 2 allée Louise et Victor Champier
BP 30329, 59056 Roubaix, France.
Email: ahmad.labanieh@ensait.fr

Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016

2 Textile Research Journal 0(00)
of the needles. Tube rapiers of bias yarns displaces only
transversely with respect to the loom main axis. And
the bias yarns are folded when they reach the preform
edges with keeping them in the same layer resulting in
formation of a zigzag non-uniform bias yarn layer.25
The bias yarns layer could be placed in any layer in
through-the-thickness of the preform.
In order to obtain a pair of successive opposite uni-
form edge-to-edge bias yarns layers within multiaxis 3D
woven fabric, Bilisik and Mohamed23,24 have developed
another weaving technique using a tube carrier. Each
bias yarn is fed from individual bobbins, then it is
passed through one tube. The tubes move transversely
inside a box and when a tube reaches the fabric edge, it
is shifted up or down to the next opposite bias yarns
layer so it changes its orientation form (y /+y ) to
(+y /y ). The filler yarns and the binder yarns are
inserted in the same manner as the tube rapier weaving
method by means of rapier needles. A special reed is
used on this loom to face the trapezoidal weaving zone,
characterizing the multiaxis weaving process. In this
reed, the inter-blades space decreases as it advances
toward the preform formation line. That allows the
friction occurring between the inclined bias yarns and
the reed blades in the trapezoidal weaving zone to be
reduced. However, this type of reed still damages the
in-plane yarns24 where rotation of blades around its
own vertical axis is required to keep its side face parallel
to the yarn axis.
In both techniques, two opposite bias yarns layers
oriented in +y and y are inserted with no possibil-
ity to separate them by a warp yarn layer (0 ). A high
inter-layer angle (2y ) causes less interlaminar resist-
ance likewise in the laminate composite where high
delamination stresses at the free edge of the structure
is observed in the case of an important angle between
successive lamina.10,26,27
In the GEMTEX laboratory, novel multiaxis 3D
weaving loom prototype is designed and realized in
order to produce a multiaxis 3D woven preform with
the possibility to separate the two opposite successive
bias yarn layers (y ) by warp yarn layer (0 ).
Consequently, a better interlaminar resistance could
be assumed for the produced impregnated preform in
comparison with the produced preforms using tube car-
rier and rapier carrier techniques. Also on this loom,
the fabric width is controlled and it is maintained equal
to the weaving zone width during weaving process.
That allows minimizing degradation of warp and bias
yarns mechanical properties caused by friction with
reed blades.
In the present research paper, the achieved develop-
ments for multiaxis 3D weaving technology are pre-
sented. Moreover, geometrical characterization is
conducted in order to describe the geometry of the
Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016
yarns inside the impregnated preform. Then the geo-
metrical properties of the manufactured preform are
compared with those of multiaxis 3D woven preforms
produced by a tube carrier weaving technique and a
tube rapier weaving technique.
Material
The multiaxis 3D woven preform is composed of multi-
layer of four in-plane yarn sets (warp, filler and bias
yarns in +y and y direction). These yarn sets are
defined according to the orientation of their main axis
relative to the loom main axis. Figure 1 shows sche-
matics of the architecture of the produced multiaxis
3D woven preform. The X-axis refers to the loom
main axis and the Z-axis refers to the loom vertical
axis. Figure 2 shows a top view of the produced
preform.
From the top view of the preform schematic
(Figures 1(c) and 2), the warp yarns could be seen par-
allel to the loom axis so they are termed 0 yarns. They
are arranged in four layers in through-the-thickness of
the preform (Figure 1(a)). The filler yarns are laid down
across the preform width along with Y-axis so they are
termed 90 yarns (Figures 1(c) and 2). Three duplicated
filler yarns are inserted simultaneously. Two of them are
inserted on the two outer preform faces (upper face and
lower face) and the third one is inserted at the preform
mid-plane (Figures 1(a) and (b)). The bias yarns are laid
down in +y and y direction relative to the loom axis
and they are inserted in form of a pair of opposite suc-
cessive layers (y ). The opposite bias layers are sepa-
rated by a warp yarn layer (Figure 1(a)). Two pairs of
bias yarn layers are arranged in the preform thickness
and they are symmetric relative to the preform mid-
plane.
Thereby, the present preform is made of 11 in-plane
layers in the following sequence according to the
yarns orientation relative to the loom main axis: (90 /
0 /+y /0 /y /90 /y /0 /+y /0 /90 ). The produced
preform is balanced and symmetric to the mid-filler
yarns layer (90 ).
Between the in-plane yarns, there are no interlace-
ments and they are locked into position by binder
yarns. The binder yarns are separated alternatively
into two sets (upper and lower) relative to weaving
zone mid-plane. For each weaving cycle these two sets
alternate their position passing throughout the in-plane
layers in the weaving zone and over the last outer filler
yarns. So, the path of the binder yarn in this architec-
ture is similar to the orthogonal architecture of the 3D
woven preform. Furthermore, the separation of binder
yarns into to upper and lower layer allows simultan-
eous insertion of two outer filler yarns. As a result, the
two outer filler yarn layers are symmetric.
Labanieh et al. 3

Figure 1. : Schematic of multiaxis 3D woven preform: (a) front view, (b) side view and (c) top view.

3. Bias yarns path pattern across the preform width.

Architecture characteristics of the bias yarns layer
Concerning the architecture characteristics of the bias
yarn layer in multiaxis 3D woven preform, four basic
characters, which are associated to the used multiaxis
weaving technique, could be defined as follow:
4. Uniformity of the bias yarn layer. The bias yarn alter-
1. Number of associated bias yarns layers formed by the
multiaxis technique device (bias yarn positioning
apparatus). Single independent bias yarns layer or
pair of inherent opposite (y and +y ) layers of
bias yarns is formed.
2. Number and position of bias yarns layers in through-
the-thickness of the produced preform.
When the bias yarn does not extend the entire
fabric width, a ‘‘zig-zag’’ pattern is obtained25
(Figure 3(a)). While, when all bias yarn extends
across the entire preform width an ‘‘edge-to-edge’’
pattern is produced25 (Figure 3(b) and (c)).
nates its orientation from (y /+y ) to (+y /y )
when it reaches the preform edge. If the bias yarn is
folded to the next opposite bias layer, a pair of uni-
form bias layers is obtained (Figure 3(b)). Figure 3(e)
depicts the path of a bias yarn guide on the position-
ing apparatus, where the continuous line refers to the
upper layer and the dashed line refers to the lower

Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016

4 Textile Research Journal 0(00)

Figure 2. : Top view of the produced multiaxis 3D woven preform with an illustration the considered unit cell.

Figure 3. (a) Zigzag pattern of bias yarns and (d) the path of bias yarn guide. (b) Edge-to-edge pattern with uniform bias yarn layer
formation and (e) the corresponding path of bias yarn guide. (c) Edge-to-edge pattern with non-uniform bias yarn layer formation
(resultant layer order for each zone is shown in red) and (f) the corresponding path of the bias yarn guide.

Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016

Labanieh et al. 5

layer. Contrariwise, if the bias yarn is folded and
kept in the same layer, non-uniform two bias yarn
layers are formed relative to the stacking sequence
(Figure 3(c)).9 Figure 3(f) depicts the path of a bias
yarn guide producing non-uniform layers. Four
zones with different layers sequence are produced
on the already produced pair of layers
(Figure 3(c)), whereas the layer sequence is the
same in the uniform configuration. Otherwise, pro-
ducing uniform bias layers requires necessarily
rotating feeding system for bias yarns, as is noted
from the guide bias yarn path (Figure 3(e)). That is
to prevent intertwining of bias yarns while fabric
progresses and to guarantee continuous production.
However, this feeding system is not required for
producing non-uniform bias layers as is illustrated
in Figure 3(f) representing the path of bias yarn
guide. An individual tension-controlling apparatus
is needed to maintain constant yarn tension during
the weaving process as the bias yarn’s path
changes.
number of each yarn type per one unit cell of the struc-
ture, the number of yarns per layer and number and
order of in-plane yarn layers, are also listed in Table 1.
The unit cell of this structure is defined as the repeated
smallest unit of the structure on the mesoscale having
the same geometrical and architectural properties
across the preform (Figure 2).
The geometrical and architecture properties of the
manufactured preform will be compared with those of
preforms produced by means of the tube rapier weaving
technique22 and the tube carrier weaving technique.23,24
Therefore, the manufacturing and weaving parameters
of these preforms are also presented in Table 1, as
reported by Bilisik.25
In the present produced preform, Kevlar fibre is used
for the binder yarn unlike the in-plane yarns where
glass fibre is used. That is because of high bending
curvature accomplished on binder yarns during weav-
ing process when they pass throughout the weaving
zone to alternate their position and to create an appro-
priate shed to insert the filler yarns.

In the present multiaxis 3D woven preform, the Method

formed bias yarn layers are uniform with an edge-to-
edge pattern.
Manufacturing and weaving parameters
For the produced preform on the present prototype
loom, the manufacturing parameters, involving density
and linear density of the used yarns, which are listed in
Table 1. Also, the weaving parameters, consisting of the
Multiaxis 3D weaving loom
As was mentioned earlier, the basic weaving operation
required on the loom to produce multiaxis 3D woven
structure is the transversal displacement of bias yarns in
the weaving zone. Where, the bias yarns have to be
moved one step for each weaving cycle transversely
with respect to the loom main axis, which corresponds
to the warp yarns feeding direction.

Table 1. Manufacturing and weaving parameters

Guide blocks Tube rapier25 Tube carrier25

Material (density [g/cm3])

In-plane yarns Glass (2.58) Carbon Carbon
Binder yarns Kevlar (1.44) Carbon Carbon

Linear density [g/m]  number of yarns per unit cell

Warp yarn 2.4  3 0.398  1 0.398  1
Filler yarn 2.4  4 0.198  2 0.198  2
Bias  y yarn 2.4  2 0.398  2 0.398  2
Binder yarn 0.172 0.198 0.198

Number of yarns per layer  number of layers

Warp yarns 18  4 layers 32  2 layers 32  2 layers
Bias  y yarns 20  4 layers 32 rows  2 layers 32 rows  2 layers
Binder yarns 19 32 32
Filler yarn per insertion Double picks  3 layers Double picks  3 layers Double picks  3 layers

Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016

6 Textile Research Journal 0(00)
An experimental and manual driven prototype of
multiaxis 3D weaving loom has been designed and man-
ufactured in the GEMTEX laboratory. On this loom, a
new apparatus using guide blocks technique has been
elaborated to accomplish this requirement. Also, the
conventional weaving operations, such as shedding
(binder yarn insertion), beating-up and take-up, are
adapted for this particular movement of the bias yarns.
The basic weaving operations realized on the loom
to wave a multiaxis 3D woven structure are: warp, bias
and binder yarn feeding, bias yarn positioning in the
weaving zone, binder yarn insertion (shedding), filler
yarn insertion, beating-up and take-up. A scheme of
these weaving systems on the GEMTEX loom is pre-
sented in Figure 4.
The warp, bias and binder yarns are fed to the weav-
ing zone, shown in Figure 5, from bobbins mounted on
braider bobbin carriers which are equipped with a ten-
sion compensation device serving to maintain the yarn
tension constant while weaving process (Figure 6(a)).
There, the bobbin is kept in position on the carrier
without rotation, to release the yarn, via a lock until
the yarn tension (F) surpasses the set tension magnitude
by ‘‘spring tension’’ (Figure 6(b)). The bobbins of warp
and binder yarns, which form one layer, are regrouped
into one feeding unit and their carriers are fixed to the
machine frame. The bobbin carriers of bias yarns are
attached to rotating chain (Figure 7(a)), and that
enables the transversal movement of bias yarns in the
weaving zone without entanglement. The bias yarn
bobbin on the upper side of the chain, which feeds
the yarns in a direction +y for instance, moves trans-
versely (along Y-axis) with the chain rotation until it
reaches the fabric edge then it turns to the bottom side
Figure 4. Schematic view of multiaxis 3D weaving loom prototype illustrating the different weaving systems.
Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016
of the chain and it continues feeding the yarn but in the
opposite direction y . This movement of the bobbin
carriers is associated with the movement of the yarn
guide block on the yarn positioning apparatus in the
weaving zone. The passage of the bobbin carriers from
a side of the chain to the opposite one corresponds with
folding the bias yarn on the fabric edge from a layer to
the next one. This folding operation requires an extra
yarn length with keeping the yarn tension constant that
is ensured by the individual feeding and tension con-
trolling of the bias yarns. So, the group of bobbins
attached to one chain feed the yarns forming a pair
of bias yarn layers in opposite orientations. They are
separated by a warp yarn layer by means of a guide bar,
placed in the chain centre, through which the warp
yarns are passed from the feeding bobbins to the pos-
itioning apparatus (Figure 7(a) and (b)).
The bias yarns of one unit cell are handed to the
weaving zone through an individual movable guide
block arranged in a positioning apparatus (Figures 5
and 7), while the warp and binder yarns enter the weav-
ing zone through the stationary guide bar attached to
the machine frame (Figure 5). The guide bar, as the
guide blocks, distributes the yarns across the fabric
width. They also manage their position in the weaving
zone to create gaps between them suitable for insertion
of the binder and filler rapiers.
In the bias yarn positioning apparatus, the tongue
and groove technique is used where the guide block has
grooves on two of its lateral faces and tongues on the
two other faces. These grooves and tongues fit with
slots and projecting strips made on the internal faces
of the apparatus frame. So the guide blocks can slide
across the apparatus frame as well as they can slide on
Labanieh et al. 7

Figure 5. Weaving zone on the constructed multiaxis 3D weaving loom prototype.

Figure 6. Braider bobbin carrier with tension compensation device (a), front cut view of braider bobbin carrier illustrates tension
compensation device principle (b).

Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016

8 Textile Research Journal 0(00)
Figure 7. (a) Bias yarn positioning apparatus using the guide block technique with the rotating feeding unit. (b) The two operating
steps to move the bias yarns transversely along Y-axis for each weaving cycle.
each other. For the warp yarn layer inserted between
the two opposite bias yarn layers, they are passed
through a guide bar having lateral face form consistent
with that of the guide block. This guide bar is kept
stationary when the guide blocks slip between the bar
and the apparatus frame.
The present loom is equipped with two bias yarn
positioning apparatus (Figure 5) but they are actuated
in opposite direction to obtain two symmetric pairs of
bias yarn layers with respect to the fabric mid-plane.
For each weaving cycle, a transversal motion of two
steps is performed to give the bias yarns an orientation
inside the preform in y relative to the warp yarns
axis. In addition, a folding operation is realized for
the bias yarns on the two-preform edge from bias
layer (+/y ) to the opposite bias layer (/+y ).
These steps are shown in Figure 7(b). In the first step,
the upper and lower guide block rows on the apparatus
are moved horizontally along with the Y-axis one step
distance. This distance is related to the unit cell dimen-
sion in the filler direction (Lf) (Figure 2). In the second
step, the two right and left vertical columns of the guide
block located on the two apparatus edges are moved
down and up one step vertically.
The y angle of the bias yarns within the fabric is
controlled by the ratio between the two unit cell dimen-
sions (in warp and filler directions). The unit cell
Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016
dimension in the filler direction is related to the
binder yarn count per unit length as well as a warp
yarn. While its dimension in the warp direction is set
by the step distance of the fabric take-up device, which
is related also to the filler yarn count per unit length.
Consequently, at the end of these two steps all guide
blocks are displaced transversely one step, whereas the
central warp yarns are kept in position. The bias yarns
on the two fabric edges are folded to the next opposite
bias yarns layer.
The binder yarns are passed through rapiers, which
are distributed alternatively into two groups on upper
and lower sides of the weaving zone (Figures 5 and 8).
The binder rapiers move normal to the weaving zone
and pass throughout it to alternate the binder yarns
position (up/down) and create suitable shed to insert
the filler yarns. The rapier is used instead of the
heddle which is used in the conventional weaving pro-
cess for shedding operation, to enable the transversal
displacement of bias yarns. At the beginning of each
weaving cycle, the rapiers have to move out of the
weaving zone. A supplementary tension compensation
device is used for the binder yarns to recompense the
extra yarn length required when the rapiers move up/
down (Figures 4 and 8).
A simple rapier system is used to insert the filler
yarns across the weaving zone width and it is similar
Labanieh et al. 9

Figure 8. Insertion of binder rapier throughout the weaving zone (a), first insertion of filler yarns (b), move back of the binder
rapiers and insertion of reed blades throughout weaving zone (c), move reed forward to pack filler to fabric (d).

to that used on a multiaxis 3D weaving loom with tube
carrier technique.24 This system consists of three hook
rapiers and two engaging rods on both weaving zone
sides (Figures 5 and 9). The three filler rapiers are
inserted simultaneously from a weaving zone side to
the opposite one to pick up three filler yarns. The inser-
tion location of filler yarns into the weaving zone
between the warp and bias yarn layers and binder
yarns are shown in Figures 1 and 8(b) and (c).
In the weaving zone, the width ratio is defined as the
ratio between the weaving zone width at warp and bias
yarn positioning apparatus and the fabric width at the
fabric formation line which is affected by the fabric
shrinkage (Figure 10). When the width ratio is less
than one, which means that the warp yarns are not
any more parallel to the loom axis so the weaving
zone no longer has a rectangular form. Consequently,
high friction is produced between the yarns and the
reed blades resulting in degradation of the warp yarns
mechanical properties and short life of the reed blades.
Therefore, it is important to keep the width ratio equal
to one, namely keeping the weaving zone form
rectangular.
On the 2D weaving loom, the fabric shrinkage is
produced due to the filler yarn waviness. Thus, in
order to keep the width ratio equal to one, two temples
are used on both fabric edges at the fabric formation
line (Figure 10(a)).
On a multiaxis weaving loom, the shrinkage ratio for
multiaxis structure is much more important compared
with the 2D woven fabric because the folded bias yarns
press the fabric literary inwards (Figure 10(b)). It is
affected by the tension (F) applied on the bias yarn
by the feeding system and fabric take-up device.
However, a temple could not be used to hold the
fabric edge because of the high fabric thickness pro-
duced on the present loom and the need to fold the
bias yarns on the fabric edge. Consequently, the
width ratio on the multiaxis weaving loom is less than
one, namely a trapezoidal weaving zone form. In this
case, the standard reed, which has a fixed inter-blades
space, could not be used because it will damage the

Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016

10 Textile Research Journal 0(00)

Figure 9. Position of the bias yarns in the weaving zone: (a) at the beginning of the weaving process (initial position), (b) after
operating the transversal displacement.

Figure 10. Top view of the weaving zone formed on a conventional weaving loom (a) and on a classic multiaxis weaving loom (b).

warp and bias yarns as a result of the high abrasion
between the yarns and reed blades. Furthermore, warp
and bias yarns count per unit length will be distorted
and uneven across the fabric width. For tube carrier
weaving loom,23,24 the width ratio is about 1/4.5, 1/
5.55 and 1/8.23 (see Table 5 below). In order to avoid
the in-plane yarns damage by conventional reed,
a special reed is designed in which the inter-blades
space decreases as the reed advances towards the
fabric from its back position near the yarn positioning
apparatus. However, abrasion still occurred even
though this special, more complicated reed25 was
used, where rotation of the blades around their own
axis is also required to keep its side surface parallel to

Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016

Labanieh et al.
bias and warp yarns axis. On the present prototype
loom, another technique has been developed based on
maintaining the width ratio equal to one where a small
engaging hook is inserted between last two bias yarns
on the two preform edges (Figures 5 and 9) at the
beginning of each weaving cycle and before displacing
the bias yarns in the weaving zone. The hooks accom-
pany the fabric on the take-up device. As a result, bias
yarn on the fabric edge will be folded over the inserted
engaging hook instead of being folded over the last
binder yarn (Figures 5 and 9). That prevents the folded
bias yarns to press fabric literary causing width shrink-
age. Thereby, the preform width is held even to weaving
zone width and the weaving zone form becomes rect-
angular (Figure 9). A reed with fixed inter-blades space
is used with less abrasion as the yarns are kept parallel to
reed blades. Otherwise, that maintains uniform yarns
density along with the filler direction.
The reed blades have to be moved out of the weaving
zone for each weaving cycle, as with the binder rapiers,
due to the transversal movement of the bias yarns.
Therefore, an open reed is used on the present loom
with two movement steps. In the first step, the reed
blades are inserted throughout weaving zone along
the Z-axis after insertion of the filler yarn
(Figure 8(c)). As with the binder rapiers, the reed
blades have to be inserted exactly at the created gaps
by crossed bias yarns and the warp yarns in order to
prevent yarns degradation. They are inserted as near as
possible to the positioning apparatus, where the gap
width is maximum, and behind the inserted filler
yarns (Figure 9(b)). In the second step of the reed
movement, the reed is moved forward along with the
X-axis to pack the inserted filler yarns into the fabric
(Figure 8(d)). Then, the reed blades are driven out of
the weaving zone and they are moved back toward the
positioning apparatus.
The produced fabric is a multi-layer structure with
an important thickness so a take-up system with trans-
lational motion is used to take the formed fabric out of
the weaving zone.
Manufacturing process
The manufacture process on the present multiaxis 3D
weaving loom consists of a series of operating steps for
the different weaving systems with predefined order,
these steps are repeated for each weaving cycle.
1st step: following the last weaving cycle, the warp and
bias yarns are parallel to loom axis and the binder
rapiers, filler rapiers and reed blades are out of the
weaving zone. Two engaging hooks are inserted
between the two last bias yarns on both fabric edges
(Figure 9(a)).
Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016
11
2nd step: the guide blocks of the bias yarn positioning
apparatus are moved one step. So, the + y and y
bias yarns are crossed in the weaving zone and they
are no longer parallel to the warp yarns as shown in
Figure 9(a).
3rd step: the rapiers of the binder yarns on both weav-
ing sides alternate their position (move up/down) to
create appropriate shed to insert the filler yarns
(Figure 8(a)).
4th step: the three rapiers of filler yarns are inserted
simultaneously across the weaving zone width to pick-
up three filler yarns, and then they are taken back
(Figures 8(b) and 9(a)). So duplicated three filler
yarns are inserted near to the yarn positioning appar-
atus where the gap between layers is higher. Two
engaging rods are used on both weaving zone edges
to pick up the filler yarns as the yarns are released
from the rapiers and these rods accompany the reed
motion toward the fabric in the next step to keep the
filler yarns in the right position.
5th step: the binder rapiers are moved back to their
initial position out of the weaving zone. Then the reed
is moved up and its blades are inserted throughout the
weaving zone (Figure 8(c)). Then, it advances toward
fabric to pack-up the inserted filler yarns (Figures 8(d)
and 9(b)).
6th step: the reed is moved down and back to its initial
position.
7th step: a second set of filler yarns is inserted and
packed up to the fabric. So the filler insertion and
beating up operation are effectuated twice for one
weaving cycle which forms one row of unit cell
along with filler yarn direction.
8th step: the formed fabric (one row of unit cell) is
moved out of the weaving zone by actuating one step
of the take-up device, so that the tension of warp and
bias yarns increases and a suitable length is released
from the feeding system to keep the set tension mag-
nitude by the tension compensation device.
Preform impregnation
A multiaxis 3D woven preform has been manufactured
on the GEMTEX loom prototype, then it has been
impregnated with the resin epoxy SR 8200 via the
Vacuum Assisted Resin Transfer Molding Process
(VARTM). This resin has been hardened by SD 7206
hardener at 24 C for 10 days.
Geometrical characterization
The geometrical parameters of a woven preform could
be subdivided into: yarn parameters and unit cell par-
ameters. The yarns parameters describe the geometry of
12
the yarns inside the preform and they involve yarn
cross-section area and the two major and minor dimen-
sions (width and thickness) of the yarn cross-section.
Also the packing factor of the composed filaments
inside the yarns denoted Pf, the bias yarn orientation
angle inside the structure denoted y and the yarn crimp
percentage in the through-thickness direction, denoted
e. The unit cell parameters describe the repeated char-
acterizing unit of the woven architecture. They include
the two in-plane unit cell dimensions along with the
warp and filler yarns directions, denoted Lw and Lf,
respectively (Figure 2), the total unit cell thickness
denoted H, the areal density of the preform, denoted
Suc, which quantifies the mass of the dry textile preform
per one square centimetre, the fibre volume fraction
(FVF) which quantifies the fibre volume relative to
the unit cell volume, and the proportions of each com-
ponent yarns type relative to the total volume of fibres.
The basic yarn and unit cell parameters are mea-
sured by means of microscopic observation of the
impregnated preform cross-section at specific cut
planes. Four cut planes are defined to obtain a suitable
description of the component yarns within the
Figure 11. Captured micrographs for a unit cell of impregnated preform at the four mentioned cut plane.
Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016
Textile Research Journal 0(00)
structure. They are specified depending on the position
of the binder yarn and the crossing point between the
two opposite-bias yarns. In Figure 11, a top view of a
representative unit of the impregnated preform showing
only the bias and binder yarns path is illustrated. On
this representative schema the four cut planes are
defined. Two cut planes are in warp direction and the
two others are in filler direction. For the two cut planes
in warp direction, one passes through the binder yarn
(denoted ‘‘warp a’’) and the other is at the middle
between two binder yarns (denoted ‘‘warp b’’). For
the two planes in filler direction, one is when the cross-
ing point of the two opposite-bias yarns (+y and y )
is on the plane of binder yarn (‘‘filler a’’) and the other
is when this crossing point is between two binder yarns
(‘‘filler b’’).
The area and the two main dimensions (width and
thickness) of each yarns cross-section could be mea-
sured on the captured micrographs by means of
image-j software by outlining the yarn cross-section as
shown in Figure 11. In the same manner, the dimen-
sions of the unit cell (Lw, Lf, H) could be measured.
Then the bias yarn in-plane orientation could be
Labanieh et al. 13

deduced by tangent function for the warp length of the
unit cell to the filler length.
The through-the-thickness crimp percentage (e) of
filler yarns is measured on the captured micrographs
‘‘filler a’’ and ‘‘filler b’’. Here, the yarn length, which
corresponds to the yarn centre line length (L0 ), denoted
real length, is measured for predefined straight distance
(L) on the preform, denoted apparent length. The yarn
centre line is defined as a spline passing through the
midpoint of vertical segments corresponding to the
yarn thickness as shown in Figure 11 on the ‘‘filler b’’
micrograph. Then the crimp percentage is computed as
follows e ¼ (L0  L)*100/L. In the same manner, the
crimp percentage of warp yarn was measured on the
‘‘warp b’’ and ‘‘warp a’’ cut plane and that of the
binder yarn on ‘‘warp a’’ cut-plane.
The packing factor could be computed based on the
measured area of the yarn cross-section (S [mm2]), the
linear density of the yarns (l [g/Km]) and the fibre
density (r [g/cm3]).
103
pf ¼
Sr
The density measurement method is implemented to
compute the fibre volume fraction in the impregnated
preform. This method involves the measurement of the
density of the produced composite part in addition to the
density of the component yarns and that of the resin.28
The proportion of each yarn type could be evaluated
by the analytical model presented previously by the
authors.29 This model is based on a simplified approxi-
mation concerning the in-plane yarn path within the
structure with constant cross-section area along with
its path.
Results
The packing factor, the area, the two dimensions and
the aspect ratio, which indicates the variation in the
cross-section shape, of the yarns cross-section are mea-
sured on the micrographs at each cut-plane and the
mean values are listed in Table 2.
On the ‘‘warp a’’ cut-plane micrograph (Figure 11),
three cross-sections are distinguished for the filler yarn
depending on its location in through-the-thickness of
the preform. On the outer surface of the preform
when the binder yarn passes over the filler yarn, its
cross-section become more compressed with a semi-
elliptic shape, denoted ‘‘filler outer under binder’’
(Figure 11), resulting in high packing factor value
(Table 2). While the filler yarn on the opposite outer
preform surface, denoted ‘‘filler outer’’ (Figure 11), has
a lower packing factor value (Table 2) with an elliptic
shape where there is less contact pressure on the yarn
outer side (no binder yarn). At the preform mid-plane,
the filler yarn, denoted ‘‘filler inner’’ (Figure 11), has
less contact pressure applied from the surrounding
yarns compared with ‘‘filler outer under binder’’
where the in-plane yarns have no interlacement. So,
the filler-inner yarn is more rectangular with lower
packing factor. The variation of the shape and area
ð1Þ of the filler yarns cross-section along its path could be
followed by observing these cross-section parameters
on the ‘‘Warp b’’ cut-plane also. On this cut-plane
(Figure 11), only two cross-sections are noted; filler-
outer and filler-inner with no binder yarn at this
plane. So the shape and area of the cross-section of
the filler-outer yarns change along with its path due
to the passage of the binder yarn. The differences in
the area and the aspect ratio of the filler-outer under
binder yarn section relative to the filler-outer section
are 16.3% and 10.47%, respectively. Otherwise, the
coefficient of variations of the area and the aspect
ratio of the filler-inner section between the ‘‘warp a’’
and ‘‘warp b’’ cut-planes are listed in Table 2. In the
same manner, the variation of the area and the shape of
the cross-section of the warp and binder yarn along
with its path is observed through the coefficient of vari-
ation of these parameters between the ‘‘warp a’’ and

Table 2. Mean values of the packing factor, area, two main dimensions (width and thickness) and aspect ratio of the yarns cross-
section with the coefficient of variation (CV) of these values between the different cut-planes

Area Width Thickness

Packing [mm2] mean [mm] mean [mm] mean Aspect ratio
Yarns factor (CV%) (CV%) (CV%) mean (CV%)

Warp 0.73 4.05 (11.87) 6.86 (3.84) 0.75 (27.83) 9.68 (31.93)
Filler-inner 0.58 2.9 (6.01) 4.85 (26.61) 0.6 (30.56) 8.76 (54.52)
Filler- outer free 0.55 3.24 4.98 0.73 6.78
Filler-outer under binder 0.65 2.71 4.26 0.7 6.07
Bias 0.62 2.98 (5.54) 4.51 (5.94) 0.74 (12.66) 6.25 (16.67)
Binder 0.9 0.13 (0.02) 0.93 (0.23) 0.14 (0.02) 6.52 (2)

Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016

14
Table 3. Mean and standard deviation (s) of the measured
thickness and the two unit cell dimensions for the impregnated
preform on four cut-planes
H [mm] Lw [mm] Lf [mm]
Section Mean s Mean s Mean
Warp a 6.98 0.12 9.71
Warp b 7.02 0.10 9.64
Filler a 6.67 0.04 10.37 0.22
Filler b 6.81 0.03 10.19 0.29
‘‘warp b’’ cut-plane. Similarly for bias yarns, where the
coefficient of variation of these parameters is observed
between the four cut-planes (Table 2). From this obser-
vation, an important variation is noted regarding the
warp, bias and filler-inner yarn cross-section shape
along its path. However, less variation is noted regard-
ing the cross-section area. This shape variation is
affected by the yarns rearrangement inside the struc-
ture, which is attributed to the open weave structure
(inter-yarns gap) of the produced fabric and to the
applied pressure in the through-the-thickness direction
of the preform by the binder yarns, in addition to the
applied pressure during the impregnation process.
Consequently, the in-plane yarns distort and displace
(transversely and through-the-thickness) inside the
structure in order to have lower internal energy. The
mean values of the measured inter-yarns gaps on
the same layers are 0.28, 0.35, and 0.01 mm for warp,
bias, and filler-inner yarn, respectively. Furthermore, as
a consequence of this rearrangement, a variation of the
unit cell thickness is observed between the four cut-
planes sections and is listed in Table 3. The inter-yarn
gape (open weave) could be managed via the yarns
linear density, their count per unit length and the unit
cell dimensions.
The crimp percentage of the warp and filler yarns
yarn in the through-the-thickness direction of the
impregnated preform are measured and listed in
Table 4. The too low crimp percentage is related to
the preform architecture where no interlacement
between the in-plane yarns. However, for the outer
filler yarns, a higher crimp percentage is noted because
of the path of the binder yarn, passing over the outer
filler yarns when it alternates its position. Contrariwise,
a high crimp percentage is measured for binder yarn as
it passes throughout the preform thickness twice for
each weaving cycle (Figure 11).
The unit cell dimensions of the impregnated preform
are measured on the captured micrographs and they are
listed in Table 3. The fibre volume fraction is computed
(Table 5) based on a density method where the mea-
sured density of the composite is 1.77 g/cm3 with a
Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016
Textile Research Journal 0(00)
Table 4. Crimp percentage of warp, filler and binder yarn in the
through thickness direction of the impregnated preform
Cut plane Crimp [%]
Warp yarn Warp a 0.14
s Filler yarn Filler a Outer 0.1
0.1 Inner 0.06
0.28 Filler b Outer 0.28
Inner 0.12
Binder Warp a 103
density value of the used resin epoxy is 1.1 g/cm3. The
density values of the used yarns are listed in Table 1.
The architecture and geometrical properties of the
manufactured preform using the constructed multiaxis
3D weaving are compared with those of the produced
preforms by means of tube rapier weaving technique22
and tube carrier weaving technique24,25 in Table 5. Like
the tube carrier technique edge-to-edge bias yarns path
pattern and uniform bias yarns layers are obtained.
Unlike the tube carrier technique, the bias yarns layer
could be placed in different order not only on the two-
preform surfaces.
The width ratio on the present loom is equal to one
corresponding to fabric width equal to weaving zone
width. That results in less degradation induced on the
warp and bias yarns by the friction with reed blades.
Also higher preform width is obtained. Like the com-
posite produced by the tube carrier weaving technique25
high fibre volume fraction is obtained. In Table 5 for all
introduced preform the proportion of bias yarns in y
is equal to that of bias yarns in +y . However, the
proportion of both bias yarns and binder yarns relative
to the unit cell volume, for the produced preform using
a guide blocks technique, is lower compared with that
of the produced preform by tube rapier and tube carrier
techniques.
Conclusion
In the present paper, a novel multiaxis 3D weaving
technique is presented. This technique is dedicated to
enabling the insertion of a warp yarn layer between two
opposite uniform edge-to-edge bias yarns layers using
the guide-block technique. An experimental manually
driven multiaxis 3D weaving loom prototype is con-
structed in this work. On this loom, the preform
width is controlled and kept equal to the weaving
zone width in order to minimize the in-plane yarns deg-
radation caused by the friction with reed blades. A pre-
form using glass and Kevlar fibres has been produced
on the present loom prototype.
The geometrical characterization method has been
conducted on the impregnated preform using captured
Labanieh et al. 15

Table 5. Architecture and geometrical parameters of the produced impregnated preform. Comparison with other techniques

Guide blocks Tube rapier25 Tube carrier25

Bias yarns path pattern Edge-to-edge Zig-zag edge-to-edge

Uniformity of bias yarns orientation Uniform Non-uniform Uniform
Bias yarns feeding Rotating braiders Fixed bobbins Rotating braiders
Bias yarn layers placement in the preform thickness Any layer Any layer Only top and bottom
Layers sequence [90/y/0/y/0/90]s [90/y/y/0/90]s [90/y/y/0/90]s
Possibility to separate opposite bias layers by warp layer Yes No No
Width ratio 1/1 1/4.5 1/5.55 1/8.23
Preform width [mm] 190 77.25 62.36 42
Bias yarn orientation  y [degrees] 43.80 34 30 40
H [mm] 6.99 2.26 2.73 3.1
FVF [%] 45.47 1.2 33.9 38.5 47.5
Warp/unit cell [%] 15.88 8.45 10.5 13.7
Filler/unit cell [%] 14.68 4.82 5.42 4.77
Bias in y /unit cell [%] 7.26 8.62 9.43 11.7
Binder/unit cell [%] 0.41 3.36 3.67 5.61

micrographs for the preform cross-section in order to

describe the yarns geometry inside the structure. A sig-
nificant variation of the in-plane yarns cross-section
shape is observed. Different packing factor values for
yarns are noticed, depending on its location in the
structure. Also, very low through-the-thickness crimp
percentages are measured for in-plane yarns as a result
of the preform weaving architecture where there is no
interlacements between in-plane yarns and because of
the binder yarn linear density compared with the in-
plane yarns.
The architecture and geometrical properties of the
produced impregnated preform has also been compared
with the produced composite using tube carrier and
tube rapier techniques.
Future works will concern, first, automation of the
constructed loom prototype, second, experimental char-
acterization of elastic behaviour, which will be compared
with behaviour computed by a numerical approach.11
Declaration of Conflicting Interests
The authors declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of this
article.
Funding
The authors received no financial support for the research,
authorship, and/or publication of this article.
References
1. Guenon VA, Chou TW and Gillespie JW. Toughness
properties of a three-dimensional carbon-epoxy composite.
J Mater Sci 1989; 24: 4168–4175.
2. Cox BN, Dadkhah MS, Morris WL and Flintoff JG.
Failure mechanisms of 3D woven composites in ten-
sion, compression, and bending. Science 1994; 42:
3967–3984.
3. Lomov S, Verpoest I and Robitaille F. Design and manu-
facture of textile composites. In: Long AC (ed.)
Manufacturing and internal geometry of textiles.
Woodhead Publishing Limited and CRC Press LLC, 2005.
4. Tong L, Mouritz AP and Bannister MK. 3D fibre rein-
forced composites. Amsterdam: Elsevier Science Ltd. UK,
2002.
5. Chen X, Taylor LW and Tsai LJ. An overview on fabri-
cation of three-dimensional woven textile preforms for
composites. Text Res J 2011; 81: 932–944.
6. Solden JA and Hill BJ. Conventional weaving of shaped
preforms for engineering composites. Composite A 1998;
29: 757–762.
7. Leong KH, Lee B, Herszberg I and Bannister MK. The
effect of binder path on the tensile properties and failure
of multilayer woven CFRP composites. Compos Sci
Technol 2000; 60: 149–156.
8. Snycerski M and Frontczak-Wasiak I. Assessment of
transversal deformation of multi-axial woven fabrics
stretched one-directionally. Fibres Textiles Eastern Eur
2006; 2(56): 29–33.
9. Kamiya R, et al. Some recent advances in the fabrication
and design of three-dimensional textile preforms: a
review. Knowl Creat Diffus Util 2000; 60: 33–47.
10. Bilisik K. Multiaxis 3D woven preform and properties of
multiaxis 3D woven and 3D orthogonal woven carbon/
epoxy composites. J Reinf Plast Compos 2009; 29:
1173–1186.
11. Labanieh AR, Legrand X, Koncar V and Soulat D.
Evaluation of the elastic behavior of multiaxis 3D-
woven preforms by numerical approach. Compos Mater
J 2014; 48: 3243–3252.

Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016

16
12. Ruzand JM and Guenot G, Multiaxial three-dimensional
fabric and process for its manufacture, International
patent WO: 94/20658, 1994.
13. Mood GI. Multi-axial yarn structure and weaving
method, United States patent: 5-540-260, 1996.
14. Bryn L, Islam MA, Lowery WL and Harries HD. Three
dimensional woven forms with integral bias fibres and bias
weaving loom, United States patent: 6-742-547, 2004.
15. Frontczak-Wasiak I and Snycerski M. Characteristic of
multi-axial woven structures. Fibres Textiles Eastern Eur
2005; 46: 27–33.
16. Nayfeh SA, Rohrs JD, Rifni O, et al. Bias weaving
machine, United State Patent: 7-077-167, 2006.
17. Lima M, Fangueiro R, Costa A, Rosiepen C and Rocha
V. Multiweave – a prototype weaving machine for multi-
axial technical fabrics. Indian J Fibre Textile Res 2009;
34: 59–63.
18. Anahara M, Yasui Y and Omori H. Three-dimensional
textile and method of producing the three dimensional tex-
tile. United States patent: 5,137,058, 1991.
19. Yasui Y, Anahara M, Hori F and Mita Y. Production of
three-dimensional woven fabric. Japanese Patent: 05-106-
140, 1993.
20. Uchida H, Yamamoto T, Takashima H, Yamamoto T,
Nishlyama S and Shinya M. Three-dimensional weaving
machine. United States Patent: 6-003-563, 1999.
21. Bilisik K. Multiaxis three dimensional weaving for com-
posite: A review. Textile Res J 2012; 82: 724–743.
Downloaded from trj.sagepub.com at University of Sydney on January 20, 2016
Textile Research Journal 0(00)
22. Bilisk AK and Mohamed MH. Multiaxial 3D
weaving machine and properties of multiaxial 3D
woven carbon/epoxy composites. Proc Amer Soc
Compos 1994; pp. 868–881.
23. Mohamed MH and Bilisik K. Multilayer three dimen-
sional fabric and method for producing. United States
Patent: 5-465-760, 1995.
24. Bilisk AK and Mohamed MH. Multiaxis three-dimen-
sional flat woven preform-tube carrier weaving. Textile
Res J 2010; 80: 696–711.
25. Bilisik K. Multiaxis 3D weaving: comparison of devel-
oped two weaving methods (tube-rapier weaving versus
tube-carrier weaving) and effects of bias yarn path to
preform properties. Fibers Polym 2010; 11: 104–114.
26. Mallick PK. Fibre reinforced composite material manufac-
ture and design, 3rd edn. Boca Raton, FL: Taylor &
Francis, 2007, p.229.
27. Hallal A, Younes R, Fardoun F and Nehme S. Improved
analytical model to predict the effective elastic properties
of 2.5 D interlock woven composites. Compos Struct J
2012; 89: 3009–3028.
28. Vasiliev VV and Morozov EV. Mechanics and analysis of
composite materials, 1st edn. Oxford: Elsevier, 2001, p.57.
29. Labanieh AR, Legrand X, Koncar V and Soulat D.
Novel optimization method to estimate the geometrical
properties of a multiaxial 3D woven preforms. Reinforced
Plastics Compos J 2013; 32: 700–712.