We are your specialist for the development and production of technical textiles and smart textiles. Embro uses computerized machines to facilitate the tailored fiber or wire placement of various threads, wire strands, wires, or heat conductors on carrier materials. This sewing and embroidery technology allows for a durable and highly flexible combination of different materials.
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Technical embroidery is our passion.
Embroidery Technology
Embro is your specialist for professional embroidery technology. Technical embroidery is a subcategory of computer aided embroidery or machine embroidery. Sometimes, it is also referred to as 3D embroidery since, during the production process, conductive wire (strands) or high-tech fibers are attached to carrier materials virtually three-dimensionally.
The field of technical embroidery can be subdivided into two disciplines:
Tailored Wire Placement (TWP) – Tube and wire laying
As indicated by the name of this production method, our machines embroider / sew wires onto textile surface structures (= carrier materials) in order to fixate them. The result is a robust and yet highly flexible composition of materials.
The placement of wire strands or conductible threads is completely arbitrary. Thus, the intended functionality (heat, antenna, sensor, etc.) can be positioned as needed. Moreover, this allows us to manufacture textile cables and flexible electronics.
Tailored Fiber Placement (TFP) – Fiber laying
In this production method, fiber-reinforced composites or carbon are “laid” onto a carrier substrate in a way so that the fiber alignment is optimized for the force progression acting upon the element. Our production process is highly efficient and just as repeatable, which means it is ideal for the manufacturing of dry preforms. Furthermore, the accurate placement of fibers / carbon allows for a zero-waste production
Cutting technology
Our modern, camera-aided cutting systems are ideal tools for the precise and efficient separation of embroidered elements. Be it our CNC cutting machines with their mechanical cutters or our CO2 laser cutting systems – either way even the most complex layout can be cut out from textile surfaces effectively, cost-efficiently, and accurately to the millimeter. Our machinery allows us to work with all kinds of materials ranging from traditional synthetic fabrics to highly specialized technical fabrics such as foam composites or laminated materials with self-adhesive films.
The advantage of our laser cutting technology lies in the fact that all edges are heat-sealed, which prevents the textiles from fraying and unsewing.
Lamination
After the embroidery process, we can refine your semi-finished products. Depending on the requirements of the given materials and your specific needs, we can perform either heat or cold lamination. When we speak about cold lamination, we mean the process of adding self-adhesive films or foil to the heating element, which then allows for the easier subsequent processing by our customers.
Using our heat lamination press, it is possible to combine the heating element with another material. Hence, the embroidered wires or wire strands can be protected from harmful environmental influences. Moreover, additional desirable properties such as conductivity or the elements’ ability to function as a patch can be integrated. This lamination process runs at temperatures of up to 200°C.
Lamination process
The lamination technology applied by Embro uses pressure and heat in order to join two textile surfaces. The lamination process is especially important for the manufacturing of functional textiles. During this process, a second textile layer is heated and pressed onto the manufactured element. The second textile layer functions to protect the manufactured component. Moreover, this technology finds application in the manufacturing of heating elements as well as in the production of flexible electronics.
Contacting and sensor integration
Per the request of our customers, we can also produce intermediate goods with electrical connections. In addition, Embro offers soldering and splicing services to its customers. This way, we can guarantee the perfect connection of our elements to other elements that were not placed on the carrier material by the use of our broad range of embroidery technologies. The different parts are joined by means of either crimping or soldering.
Moreover, the installation of thermoswitches, NTC (negative-temperature-coefficient) thermistors or other cable solutions is feasible. Even a variety of different plugs can be realized, which creates a semi-finished product that is virtually plug and play
Quality management
It is our conviction that all of our products and services must excel in terms of their quality. We understand that we can only gain and maintain the trust of our customers when complying with the highest standards. Hence, we have always adhered to international standards. While doing so, we continuously evaluated and improved our business, development, and production processes.
In order to document our efforts when it comes to quality management, we decided to become certified under DIN EN ISO 9001 in 2014. Since our commitment to working to the highest standards has not changed, TÜV Süd was able to certify us yet again
Specialist for Smart Textiles
