Textile Structure
how cloth is put together
The collection

Every essay — page 8

Page 8 of 23, continuing through the fields in the same order.

What cloth is Weaves Setting and geometry Knits and other structures Mechanics and drape Pattern and colour Compound and figured cloths After the loom Cloth doing a job

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After the loom

The cloth that comes off the loom is not the cloth anybody buys. Shrinkage as the crimp coming back, the yarn flattened and swollen, the floats raised into a nap, and the fibres entangled until the weave is no longer the only thing holding the fabric together.

The cloth a calender nip exactly fills. The share of a cloth's plan a calender leaves specular, per unit of crown line per crossing, against the cover of the lustrous system, for nips that flatten the yarn by ×1.25, ×1.5, ×2, ×3. Each curve rises while the nip binds and falls once the threads meet their neighbours; the peak is at the cover the nip exactly fills, 0.919 for ×1.25, with a share of 0.200; 0.853 for ×1.5, with a share of 0.333; 0.754 for ×2, with a share of 0.500; 0.628 for ×3, with a share of 0.667. The yarn diameter, 0.2 mm here, appears in neither the peak's position nor its height.

A calender's best cloth is the one its nip fills

A calender's lustre is a length of crown line times a width of plateau. A closer cloth has more crown line and less room to widen each thread into, and the product was expected to peak at some interior cover that would move with the weave. It does not peak at all on the cap alone — per unit of crown line it falls all the way from the most open cloth. The peak is made by the nip: a nip that flattens by f has one best cloth, the one it exactly fills, at a cover of d over the flattened width, and there the lustre is (f − 1)/f. No yarn, and no weave, moves it.

5 figures · Lustre finish One dip, two yarns: the same depth of dye. The cross-section of two cotton yarns drawn to one scale after a 20-second dip in a bath whose dye the fibres take up 10 times as strongly as the liquor holds it, each fibre shaded by the dye that reached its distance from the surface. 20 tex: 118 fibres, 167.1 µm across, dyed to 19.7 µm — 24% of its radius and 42% of its section; 74 tex: 435 fibres, 321.4 µm across, dyed to 18.2 µm — 11% of its radius and 21% of its section. The depth in micrometres is the same for both because a dip dyes a depth; the share is not, because the coarse yarn has more section behind the same ring. The fibres are drawn on a lattice and the count is computed; the affinity is an assumed value and every depth moves with its square root.

A dip dyes a depth, not a share

A yarn dyed after spinning is a cylinder the dye has to diffuse into through the liquor between its fibres, and the fibres slow it by taking dye out of the liquor as it passes. A twenty-second dip therefore dyes to a depth, some tens of micrometres, and that depth is almost the same in a fine yarn and a coarse one. So the same dip that colours two fifths of a shirting yarn's section colours a fifth of a denim warp's; eight dips deepen the shade eightfold and leave the ring where it was; and a tighter yarn rings more thinly, because packing closes the pores faster than it narrows the yarn.

7 figures · Dyeing A ring-dyed yarn worn flat, step by step. One cotton yarn dyed in a ring 20% of its radius deep, cut flat from the top by an abrader to five depths: worn to 10% of the radius, 1.9% of the yarn has gone and 0% of its width is white; worn to 20% of the radius, 5.2% of the yarn has gone and 0% of its width is white; worn to 30% of the radius, 9.4% of the yarn has gone and 39% of its width is white; worn to 45% of the radius, 16.8% of the yarn has gone and 58% of its width is white; worn to 70% of the radius, 31.2% of the yarn has gone and 74% of its width is white. The olive line is the cut face and the red bar above it is the part of the face that has reached the undyed core. Nothing is white until the cut passes the ring, and then the white arrives quickly. The section is a circle and the ring's edge is drawn sharp; a real yarn is neither, and its fibres migrate, so the core's edge is ragged.

A ring-dyed yarn whitens all at once

Rub a yarn that is dyed in a ring, and for a while nothing shows. The abrader takes off blue fibre, the cut face is blue, and the yarn looks as it did. Then the cut reaches the undyed core, and the white arrives with a vertical tangent, as the square root of the wear past the ring: one per cent of the radius more and an eighth of the width is white. A ring a fifth of the radius deep hides the first five per cent of the yarn's loss and shows half its width white by thirteen. A yarn dyed through never shows white at all. Denim's high-contrast fading is that threshold, drawn over a cloth.

6 figures · Dyeing Two ring-dyed faces worn to 5% of their mass. The faces of 3/1 twill and plain woven from the same ring-dyed 50 tex warp and undyed weft, at 24 ends and 16 picks a centimetre, each worn flat by an abrader until 5% of its thread has gone, drawn over two repeats: dyed warp dark, exposed undyed core red, weft pale, holes blank; the 3/1 twill shows 30% of its covered face as exposed core; the plain shows 17% of its covered face as exposed core. A float's crown is a line and is cut along its length; a plain weave's crowns are points and are cut through as small patches. The geometry is the plain-weave solution for these counts and setts with the floats drawn over it, which is more open than a real denim; what the figure cannot show is a denim at its real density.

A float fades late and hard, a crossing early and soft

Wear a ring-dyed face flat and the white arrives where the cut first passes the ring at a crown, which is the same depth for every weave. What differs is how much cloth has gone by then and how fast the white spreads after. A plain weave's crowns are points, cut through by almost nothing: it shows white after a fifth of a per cent of its thread and never shows much. A twill's floats are lines, cut along their length: a 3/1 twill shows nothing until more than one per cent has gone, then whitens faster than any plain weave can, 39 per cent of its face by a tenth worn against plain's 24. Denim's high-contrast fade is a float's; chambray's soft one is a crossing's.

5 figures · Dyeing A crease along a 3/1 twill's floats and one across them, worn alike. A strip of 3/1 twill of ring-dyed 50 tex warp and undyed weft folded round a 2 mm radius, the ridge drawn across the page as a dashed line, worn by a flat abrader 50 µm into the ridge: above, with the ridge running along the warp and its floats; below, running across them. Dyed warp dark, bared core red, weft pale. crease along the warp: 83% of the crease's length white, in runs 1.72 mm long on average, the longest 2.08 mm; crease across the warp: 31% of the crease's length white, in runs 0.15 mm long on average, the longest 0.17 mm. On a twill the white along the warp lies in lines as long as a float's crown, across it in dashes one end wide; on a plain weave, with no floats, both are short. What the drawing cannot show is the fibre a real crease tears loose, which blurs every edge here.

A crease across a twill fades in dashes

A garment is not worn flat. It is worn along its folds, where the ridge of a crease stands out and is rubbed first, so the fade follows the crease. On a ring-dyed 3/1 twill a crease running along the warp bares the cores of the floats that lie under its ridge, float by float, and reads as a white line broken only where each float dives: at fifty micrometres of wear, 83 per cent of its length is white, in runs of 1.7 millimetres. The same crease across the warp meets every float at one point and reads as a row of dots, 31 per cent white in dashes of 0.15 millimetres, one end wide. It bares much the same core. A plain weave's creases are dashes whichever way they run.

6 figures · Dyeing One crease at four angles to a 3/1 twill's warp, worn alike. Four strips of 3/1 twill of ring-dyed 50 tex warp and undyed weft, each folded round a 2 mm radius with the ridge drawn across the page, worn 50 µm into the ridge by a flat abrader, 24 mm of crease each. Dyed warp dark, bared core red, weft pale. along the warp (0° from the warp): 80% of the crease white, its longest white run 2.0 mm; along the twill's line (33.7° from the warp): 100% of the crease white, its longest white run 45.0 mm; two degrees off the line (35.7° from the warp): 79% of the crease white, its longest white run 15.7 mm; along the other diagonal (-33.7° from the warp): 66% of the crease white, its longest white run 1.0 mm. Along the twill's line the white never breaks, because the crease meets the crown of every end's float in turn; two degrees off, it runs as long strokes that drift off the line of crowns and come back. What the drawing cannot show is the fibre a real crease tears loose.

A crease along the twill fades as one line

A crease along the warp of a ring-dyed 3/1 twill fades as broken lines a float long, and across it as dashes one end wide. Turn the crease to the twill's own diagonal and it fades as a single white line with no break in it at all: the fold meets the crown of one end's float, then the next end's one pick along, then the next, and every crown it meets is at the same place in its float. It is the one direction in which the weave and the crease line up — and two degrees off it the line breaks into strokes whose length is a vernier's.

6 figures · Dyeing A 50 tex yarn after 1, 4, 8 dips into a fibre that fills. The cross-section of a 50 tex cotton yarn after 1, 4, 8 twenty-second dips, each fibre shaded by the dye fixed at its distance from the surface, on one scale of shade for all three. The fibre's room for dye is finite and one dip at the bath's strength fills 20% of an empty fibre's, so each dip meets less affinity near the surface than the last and carries its dye further in. after 1 dip: ring 14% of the radius deep, the surface 20% full; after 4 dips: ring 18% of the radius deep, the surface 59% full; after 8 dips: ring 24% of the radius deep, the surface 83% full. With room to spare every dip would leave the first dip's 14%. The share is assumed; nothing here measures it.

A fibre that fills dyes deeper with every dip

Dipped eight times, a ring-dyed yarn is darker than after one dip but no deeper — if its fibres have room for all the dye they are offered. They do not: every dip's dye occupies some of the fibre's room, the next dip meets less affinity near the surface, and dye that is taken up less travels further before it is taken. How much further depends on one number the dip arithmetic never needed — the share of an empty fibre's room one dip fills — and eight dips turn that number into a ring 1.15 times deeper at five per cent and 1.68 times deeper at twenty.

6 figures · Dyeing A 50 tex yarn after eight dips, with its pores open and filling. The cross-section of a 50 tex cotton yarn after eight twenty-second dips into a fibre one dip fills by 20%, each fibre shaded by the dye fixed at its distance from the surface, on one scale of shade. open pores: the ring 24% of the radius deep, the surface 83% full; the dark shade's pigment, all in the pores: the ring 22% of the radius deep, the surface 83% full; pores 90% filled at a full fibre: the ring 16% of the radius deep, the surface 83% full. One dip leaves 14%. The middle section is the most a dark denim's indigo could clog its pores, every grain placed in them; the right is a clog no denim's pigment is large enough to make.

Indigo is too little to close the pores it dyes through

Each dip of a fibre that fills carries its dye deeper, because the dye already fixed near the surface leaves less room there. But indigo is fixed as a solid, and some of it sits in the pores the next dip has to travel through, so a heavily dyed skin should also hold the next dip back. The two pull opposite ways, and which wins is decided by how much pigment there is. A dark denim's indigo, every grain of it placed in the pores, fills at most a fifth of them at the surface and takes back about a seventh of the ring's deepening — under two micrometres. The surface fills at the same rate whatever the pores do, so two cross-sections still tell the two effects apart.

6 figures · Dyeing The ring across eight dips, for each fibre. The ring's depth after each of eight twenty-second dips, where an empty fibre left in the bath for good would fill by 20% a dip. instant fibre: 14.0% after one and 23.5% after eight; τ = 20 s: 13.0% after one and 19.6% after eight; τ = 100 s: 23.1% after one and 26.1% after eight; τ = 400 s: 35.5% after one and 36.6% after eight. An instant fibre earns its ring by saturating the skin dip by dip. A slow one starts near its final depth, since it never fills its skin.

A slow fibre starts its ring deep

Every account of an indigo dip here lets a cotton fibre take its dye at once. Give the fibre a clock of its own and the ring does not simply run deeper, which is what the question seemed to ask. A clock of a few seconds makes the ring shallower, by nearly a fifth at most, and only past about twenty-six seconds does it run deeper than an instant fibre's. Two sections tell the accounts apart that one cannot: an instant fibre earns its ring dip by dip, from 14 to 23.5 per cent of the radius over eight dips, and a fibre with a hundred-second clock starts at 23 and ends at 26.

7 figures · Dyeing

Knits and other structures

Loops rather than crossings. Why a knit stretches without a bias, why stockinette curls, and why a dropped stitch runs while a woven cloth frays.

The knitted loop. One thread, bent into a course of loops, each of them drawn through the loop below. Nothing here is straight, which is why a knit extends in every direction while a woven cloth extends only on the bias.

The loop

A knit is one thread bent into loops, each drawn through the loop below. Nothing in it is straight, which is why it stretches in every direction while a woven cloth stretches only at an angle.

6 figures · Knit Why one curls and the other does not. A knitted loop is not symmetric front to back. Worked every course the same way, the asymmetries add along the edges and the fabric rolls; worked alternately, consecutive courses point opposite ways and cancel.

Why stockinette curls

A knitted loop is not symmetric front to back. Work every course the same way and the asymmetries add up along the edges; alternate them and they cancel. That is the whole difference between a fabric that rolls and one that lies flat.

6 figures · Knit One break, two outcomes. The same single break in a knit and in a weave. In the knit nothing holds the loop above the break, so the failure climbs the wale; in the weave every other thread is still held by the threads crossing it, and one thread comes loose.

Ravel, fray and run

Cut a woven cloth and one thread comes loose. Break one loop in a knit and every loop above it follows. The two structures fail in opposite ways, and the reason is topology rather than strength.

7 figures · Knit The tricot lapping. A warp-knit lapping drawn from the guide bar's movement. Each thread is coloured by the group of wales it belongs to, so a lapping that leaves the wales independent shows as several colours. This one joins them into 1 group.

Warp knitting, which is a different thing entirely

Every wale has its own thread, and if the thread never leaves its wale the fabric is a set of independent cords. Whether a lapping makes cloth is decided by a coprimality condition — the satin theorem, in a knit.

7 figures · Warp knit 1×1 rib — alternate wales to the back. A knitted fabric seen in section across the wales. Alternate wales pulled to the back fold the fabric like a concertina, so its relaxed width is a projection; pulling it wide unfolds the section and no yarn changes length while it happens.

Rib and interlock

A rib fabric is a plain knit folded like a concertina, and its enormous widthwise stretch is the fold opening out. Nothing in it is elastic, and the extension available is a cosine.

7 figures · Knit Four ways a fabric gets longer without stretching. Extension available from each mechanism, computed from the geometry that provides it. None of these numbers involves a yarn changing length; every one of them is a shape changing, and they differ by an order of magnitude.

Why a knit recovers and a woven does not

Four fabrics get longer without a single yarn stretching, and the four mechanisms are worth wildly different amounts. Three of them are recoverable and one is very nearly not, and which is which follows from where the extension came from.

6 figures · Knit What a second guide bar buys. Independent fabrics left by each lapping across 12 wales, counted by walking the wale graph and checked against the greatest common divisor of the shogs with the width. A bar that leaves more than one is not making cloth; a second bar can put right what the first could not.

What a second guide bar is for

One warp-knit bar leaves the wales in as many independent fabrics as its shog shares factors with the width. Two bars leave the greatest common divisor of both — so a pair of shogs that each fail alone can succeed together, and a pair that share a factor cannot.

6 figures · Warp knit half-cardigan as an array. One cell per needle per course, over 2 repeats each way. K knits a new loop and casts the old one off, T tucks the yarn into the loop below without casting off, M misses the needle and floats past it. The margins carry the two conditions: a wale with no K in it never casts off, and a course with no K in it is never caught by anything. Both hold here.

Knit, tuck and miss

A weave is a matrix over two symbols and a weft knit is a matrix over three. The site's central question survives the translation intact: a weave falls apart when its above-and-below relation is disconnected, and a knit falls apart when a needle never knits.

8 figures · Stitch notation Yarn per needle, by structure. Wale spacings of yarn per needle position, at one loop length. A knitted loop is 4.30 of them — Munden's constant, measured rather than derived — a float across one needle is exactly one, and a tuck is taken as a stated multiple of a loop. Everything else follows by counting, so the percentages beside the bars are not estimates.

What a tuck costs

A knitted loop is about four wale spacings of yarn and a float across one needle is exactly one, so replacing a knit with a miss removes three quarters of a loop. That much is a count. What it does to the fabric's size is not, and this essay is careful about which is which.

7 figures · Stitch notation single float as an array. One cell per needle per course, over 2 repeats each way. K knits a new loop and casts the old one off, T tucks the yarn into the loop below without casting off, M misses the needle and floats past it. The margins carry the two conditions: a wale with no K in it never casts off, and a course with no K in it is never caught by anything. Both hold here.

The float in a knit

Five rungs of this anchor have taken the float to be a length of thread on the surface with nothing holding it down. A knit has one too, and it behaves the same way in the light and the opposite way in the hand — because a woven float lengthens its thread and a knitted one shortens its fabric.

8 figures · Float rib-float in section. A two-bed structure seen in section across the wales, over 3 repeats of course 1. The front bed's loops sit on the upper line and the back bed's on the lower one, offset by 0.5 of a needle pitch because the gating is rib. Of the 2 floats in the repeat, 2 lie in the gap between the beds and 0 on a surface. The upper panel is the fabric at the machine and the lower one is the same course with the beds closed up, which is what happens when the fabric is cast off — and neither panel is a relaxed fabric, because the loops are drawn as arches of one size and a real one settles wherever the yarn's bending leaves it.

A second bed changes what a float is

Every float so far has been on a surface, because every knit so far has had one needle bed. Put a bed behind it and the yarn runs in the gap between them — and over the whole enumeration of two-bed structures, 1,248 floats of 1,272 lie inside the cloth, on no surface at all.

8 figures · Two-bed tubular, as a graph of its wales. Every wale of tubular as a node — 2 on the front bed and 2 on the back — with one chain per course joining everything that course takes yarn on, because a course is one traverse of one yarn. The nodes are filled by which component they fall into. This structure comes out as 2 fabrics: F0+F1 and B0+B1. The same answer is obtained a second way, by walking every partition of the wales and asking whether any course straddles it, and the two are required to agree.

Does a double jersey hang together

Two beds knitting with nothing passing between them are two fabrics that happen to have been made at once. Of 6,561 two-bed arrays, 1,135 are fabrics and 50 of those are two fabrics — and 28 of the 50 split across the beds rather than along them, so neither half is a layer.

7 figures · Two-bed A fashioned edge at 1 wales in 2 courses. A knitted panel narrowing by 1 wale every 2 courses, drawn at the fabric's own aspect: a wale is 1.2791 times as wide as a course is tall, which is Munden's ratio of the two published constants. The edge therefore stands at 32.60 degrees from the wale, and that angle is the same in every yarn, at every gauge and at every loop length. Marks show where the 8 transfers fall.

A fashioned edge has a quantised angle

A knitted panel is shaped by transferring loops, so its edge steps by whole wales at whole courses and its angle is the arctangent of a fraction. The available angles turn out to be the same for every plain knit there has ever been — in any yarn, at any gauge, at any loop length — because the constant they scale by cancels the loop out. There are eighteen of them, and 16.67° between the last two.

6 figures · Shaping How far a tube can be tapered by its loop. The same 10 wales by 10 courses of plain knit at the two ends of the usable loop range for a 20 tex yarn — 3.44 mm at the loose end and 2.80 mm at the tight one — drawn at a common scale in centimetres. On 240 needles the circumference falls from 192.0 cm to 156.0 cm, a taper of 18.8 per cent, and the fabric becomes 1.51 times as dense.

A tube can only be shaped by its loop

On a circular machine the needle count is the cylinder, so a seamless tube's circumference is its wale count times its wale spacing — and the wale spacing is the loop length over one constant. The loop is the only free quantity, the yarn bounds it at both ends, and what is left is a taper of 18.8 per cent bought at the price of a fabric half again as dense.

6 figures · Shaping The loop that costs nothing to extend. A plain knitted loop at rest and extended by 35 per cent, with the arcs marked. The arcs' radius is the diameter of the yarn the loop wraps, 0.167 mm, and it is set by contact rather than by the fabric's dimensions — so extending the fabric lengthens the legs and bends nothing further. The bending energy is 0.0176 N·mm at both, and the model therefore asks no force at all for an extension a woven cloth would refuse. What the drawing cannot show is what a real knit's first few per cent do cost, which is friction and yarn flattening and is not a bending property.

A knit is soft because it bends

Ask the same energy question of a woven cloth and a knitted one and the answers are not different by a factor — they are different in kind. A woven cloth's bending energy changes the moment it is extended. A knitted loop's does not change at all, exactly, over the whole of its extension, because its arcs are held to a radius by contact rather than by the fabric's dimensions.

6 figures · Knit