At the 2025 Functional Fabric Expo in Shanghai, KARL MAYER´s high performance tricot machines with high-density micro-texture knits took center stage. These fabrics offer breathability, stretch, opacity, and production efficiency, transforming UV tops, yoga leggings, polos, and commuter pants.
Six Key Advantages of warp knitted fabrics and how it works
| Advantage | How It Works |
|---|---|
| Breathable | Mesh structure & functional yarns wick sweat away in seconds |
| Lightweight | 15–20% lighter than woven fabrics at the same GSM |
| Non-see-through | Dense loops prevent “see-through” moments |
| Stretch | Spandex core gives four-way recovery |
| Cut-and-sew friendly | Knitted edges do not unravel, cutting production steps and costs |
| Textured look | High gauge & tight loops eliminate the “floppy knit” look |
Customer Spotlight – KARL MAYER China Pavilion
Fujian Highjet Industrial Co., Ltd.
Award-winning fabric: Ultra-light UV-stretch warp-knitted fabric
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World-first hidden anti-perspiration yarn
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UPF 113, inherent UV block
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Quick-dry, cool-touch, antibacterial
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Produced on Karl Mayer 2-bar HKS machines
New fabric: Warp-knitted wind tunnel shirt
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Extreme breathability
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Signature jacquard micro-texture with custom functional yarns
XYX MATERIALS Co., Ltd.
Performance-driven high-gauge sportswear fabrics
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Ideal for polos, pants, outdoor & business wear
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Net-like micro-texture made on high-gauge machines → crisper hand-feel, tech-wear vibe
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Commitment to premium branding via warp-knitted high-gauge products
Fujian Unitex Co., Ltd.
From yoga to commute – full-range high-gauge, high-density micro-texture fabrics
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Applications: underwear, swimwear, yoga, running, UV tops, mid-layers, lifestyle fashion
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2-bar warp stretch fabrics, ideal for squat-proof pants
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A professional R&D team with advantage in yarn sourcing, and Karl Mayer Warp Knitting machines ensure high quality and stability
Guangdong Golden Horizon Industrial Co., Ltd.
Mid-to-high-end functional fabrics & garments for Europe & the US
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Functional yarns and KARL MAYER 2/3/4-bar machines create micro-textures
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Focus on functional apparel for domestic and international markets, with the US as the main target.
Guangdong Derun Textile Co., Ltd.
Award-winning fabric: Seamless warp-knitted shaping fabric
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Recycled yarns, eco-friendly production and sustainability.
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Full-dull yarn directly knitted on 40-gauge machines for an amplified matte look with no white cast on dark colors.
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Tight knit: opaque, anti-snag and anti-pilling.
From Yarn to Garment:
How KARL MAYER's highly productive machines bring functional fabrics up to speed
Yarn Level
- 40-gauge extreme tightness delivers a flat, even surface for uniform finishing
- Same tightness improves waterproof coatings, keeping outer shells crisp and inner layers dry
Structure Level
- 40-gauge warp and our “micro-jacquard” turns a plain knit into a visible 3D texture — crisp and opaque
- Dense loops naturally resist snagging and abrasion, perfect for cycling jerseys and outdoor shells
Functional Finishing
- High-density greige fabric absorbs cool-touch, moisture-wicking, and antibacterial finishes more evenly and durably
- After brushing or peaching, the surface stays flat and feels “cottony”, ready for next-to-skin underwear markets
Good machines are just the starting point. Every improvement in fabric stiffness, every gram of weight reduction, and every simplification of the cutting process is the result of our customers' round-the-clock experimentation and perseverance. We will continue to work hand in hand with our customers. We will keep innovating and exploring new frontiers together.