Abstract: In a multi-layer woven fabric in which a first yarn system forms yarn layers between the opposite broad surfaces of the fabric and a second yarn system extends through the fabric thickness between the opposite broad surfaces and is interwoven with the yarn layers, at least one of the first and second yarn systems is comprised of two or more different yarn groups of different material composition disposed within different portions of the thickness of the fabric. This enables different materials such as carbon, ceramics, metals and organics to be disposed uniformly throughout the fabric thickness or to be concentrated within particular portions of the fabric thickness. In this manner multi-layer woven fabrics can be customized for particular applications in terms of their chemical, electrical, thermal, ablative, optical or other properties while retaining the advantageous structural characteristics of such fabrics. Both angle interlock and layer-to-layer weaving configurations may be used.

Abstract: Three-dimensional thick fabrics are made from a laminate of fabric plies by first inserting pointed rods through the laminate to form rows of holes after which needles are reciprocated through the different holes to pull loops of various yarns through the holes. The loops of yarns in adjacent holes are interlocked to hold the plies together. A guide releasably clamped to each yarn controls tension in the yarn while a doffing point is employed to insure that the needle passes through a loop just formed when penetrating the next hole to insure interlock of the loops. Hollow circular objects are formed by winding a length of fabric a selected number of times around a form, following which the pointed rods are used to form holes in the resulting laminate with the needles and yarns being used to form the interlocking loops through the thickness of the laminate.

Abstract: Three-dimensional thick fabrics are made from a laminate of fabric plies by first inserting pointed rods through the laminate to form rows of holes after which needles are reciprocated through the different holes to pull loops of various yarns through the holes. The loops of yarns in adjacent holes are interlocked to hold the plies together. A guide releasably clamped to each yarn controls tension in the yarn while a doffing point is employed to insure that the needle passes through a loop just formed when penetrating the next hole to insure interlock of the loops. Hollow circular objects are formed by winding a length of fabric a selected number of times around a form, following which the pointed rods are used to form holes in the resulting laminate with the needles and yarns being used to form the interlocking loops through the thickness of the laminate.

Abstract: A bias fabric having parallel, spaced-apart yarns oriented .+-.45.degree. relative to the long axis of the fabric is formed by directing one or more pluralities of the yarns back and forth across the width of the fabric and securing the yarns around pins mounted on movable conveyors at the opposite sides of the fabric. Alternatively, the yarns are mounted on strips of film with the film strips being secured to the opposite conveyors. In one preferred embodiment one or more elongated yarn laying units arranged to supply yarns through apertures along the length thereof are cycled laterally between the opposite conveyors as the conveyors are moved at a controlled speed to form a 2-ply fabric, the yarns being wrapped around pins on the opposite conveyors using an adjustable roller arrangement mounted on the shuttle or a plurality of pin mounting rings the alternate ones of which move in unison so as to engage odd and then even numbered yarns in the yarn array.