Densified Polyester Fiber Products

In addition to high-loft polyester products, we also custom-manufacture densified polyester fiber to meet the needs of a wide variety of customers. Our nonwoven fabrics can be compressed from a natural batt of 12 inches in thickness to a finished size of just a few inches, creating a very dense product. This densified polyester fiber can be used across many industries, often in place of foam. Applications include outdoor furniture, playpen mats, acoustical panels and much more. Contact us to find out how our densified fiber might solve a problem for your business.

Customized Products

Do you have special requests for your product? We are happy to customize your order. Below are some of the components that can be adjusted to meet your specific needs. Your sales representative can assist you in developing specifications for the material you need for a particular application.

Staple Polyester Composition: We use one of two grades of staple polyester in our production process. For our firm “deck-pad” and synthetic cotton products, we use a 100% recycled white polyester blend that is sourced from furniture applications in the United States. For all other products, we use premium quality virgin and semi-virgin polyester.

Denier: The denier of staple polyester is essentially the diameter of the strand. Finer deniers have a softer feel. Coarser deniers are rougher and more abrasive. Most of our products are either6 or 15 denier (or a blend of the two). However, we can manufacture products using staple polyester that is as thin as 3 denier or as thick as 45 denier.

Bonding: We bond our fiber primarily through the use of low-melt polyester, which is thermally activated when it passes through an oven. Needling also can be used to bond – either as a stand-alone process or in addition to thermal bonding. More detail on needling is provided below.

Weight: In the high-loft non-woven industry, weight is normally measured by the number of ounces per square foot. Our typical range is from 0.25 ounce to 12.0 ounces.

Loft: Our products have a standard loft (or thickness) based on common industry practices. A general rule for high-loft nonwovens is that each ounce per square foot corresponds to an inch of loft. So, a 1-ounce-per-square-foot product would be 1 inch thick. However, we have the ability to increase the loft if you desire a product that is inflated. (An inflated product includes more air with the same basis weight.) Similarly, we can decrease the loft to make a denser material.

Needling: Some of our production lines have the capability of applying a needle loom to the web prior to thermal bonding. Needling adds additional rigidity and strength to the fiber. Variables in this process include the speed of the loom (how quickly it engages the material), the depth of the penetration, and the type of needle that is used. Needled fiber is significantly stronger than products bonded in other fashions.

Firmness: Outside of needling, the firmness of a fiber product is determined by the amount of bonding polyester that is included in the formula. Over the years, our engineers have developed a standard that is the right balance between soft and firm for most customers. However, if your application requires additional rigidity (or increased softness), we can modify your product accordingly.