More Than A Spacer: KARL MAYER Opens New Possibilities In Fabric Design

Kay Hilbert discusses how the company’s latest Jacquard double-needle bar raschel machines combine higher productivity with greater design freedom for footwear, sportswear and athleisure applications.

As footwear and performance apparel manufacturers seek finer fabrics, greater functionality and shorter production runs, machinery developers face the challenge of delivering flexibility alongside efficiency. KARL MAYER’s new RDJ 7/3 and RDJ 6/2 machines address these requirements through expanded patterning capabilities and a wireless Jacquard control system.

Ahead of the company’s in-house product show at KARL MAYER (China), accompanying ITMA ASIA 2026, Kay Hilbert explains the technology behind the developments and the opportunities they create for spacer fabric manufacturers.

What market requirements have shaped the development of the RDJ 7/3 and RDJ 6/2?
Our new Jacquard double-needle bar raschel machines are designed specifically to meet the footwear industry’s requirements, where efficient production, flexibility and design versatility are key priorities.

The RDJ 7/3 and RDJ 6/2, which we will present at our product show at KARL MAYER (China), are extremely versatile and up to 70% more productive than comparable machines on the market. Shorter production times help customers respond faster to changing demand and manufacture smaller production runs cost-effectively.

At the same time, the machines offer considerably greater creative freedom. On the seven-bar RDJ, for example, manufacturers can create functional zones and integrated patterns for stability or breathability with more intricate contours and a wider range of options. Nearly round and larger openings, multidimensional surfaces, embossed effects and varied colour combinations further expand the design possibilities.

This gives our customers the freedom to develop products that would previously have been difficult to realise.

How does the finer-gauge RDJ 6/2 expand opportunities beyond footwear?
The RDJ 6/2 in gauge E 32 delivers an exceptionally fine fabric appearance. We see a clear trend towards finer fabrics and finer yarns, particularly in apparel.

Our E-32 warp knits offer a cost-effective alternative to circular-knitted fabrics for garments and open up additional opportunities in outerwear.

We will also showcase a new generation of shoe fabrics developed by our globally networked TEXTILE INNOVATION CENTER, demonstrating how these machine capabilities translate into new textile products.

Wireless Jacquard control is central to these developments. How does it simplify machine operation and maintenance?
Our wireless piezo control system replaces conventional cable arrangements with conductive tracks embedded in the Jacquard bars. This significantly reduces manual handling on the machine.

Previously, a retrofit could involve managing up to 240 cable strings, each containing 17 ribbon cables. With Wireless Jacquard, the piezo elements are simply plugged in, making the process faster and easier.

Replacing an element following a malfunction is also less complicated. In addition, operators have better access to the threads entering the knitting zone.

What does this technology make possible in machine design and fabric development?
For us as machine builders, the potential extends well beyond easier handling. Wireless Jacquard creates space for more than two Jacquard bars and allows the split Jacquard to operate counter-lapped.

These capabilities create new possibilities for spacer fabrics with appearances and functions that could not previously be achieved. The RDJ 7/3 and RDJ 6/2 being presented in Changzhou offer an initial view of this potential. We also plan to introduce the technology into our RASCHELTRONIC models in the near future.

Wireless Jacquard bar control is therefore a key technology for us. We have developed our own solution to eliminate electrical hazards for operators while meeting our quality requirements.

The system also provides scope for further technological additions, which we will pursue to increase the value our machines deliver to customers.

What can visitors expect from the KARL MAYER (China) Product Show?
I am particularly looking forward to direct discussions with existing customers and new participants across the textile value chain.

The product show gives us an opportunity to present nearly our entire machine portfolio and demonstrate its potential through innovative spacer fabrics. Visitors will be able to see the connection between machinery capabilities and textile development firsthand.

Teams across our locations have worked closely together to prepare this comprehensive machine and textile show, and I am proud of the result.

Together with the capabilities of our TEXTILE INNOVATION CENTER in Changzhou, we can demonstrate the opportunities our RDJ machines and textile solutions offer, particularly in growth markets such as footwear, sportswear and athleisure apparel.