Plush material is primarily made by inserting extra yarns into the fabric during either the weaving or knitting process, creating a dense, soft surface known as a pile, which can then be cut to various lengths and shapes. This intricate method gives plush its distinctive soft and luxurious feel.
Understanding Plush Fabric Production
Plush fabric, renowned for its soft, deep pile, is a type of textile characterized by its velvety texture. Its creation involves specialized techniques that introduce additional fibers to form a raised surface. This manufacturing approach allows for significant versatility in material composition and final texture, making plush a popular choice for everything from clothing to toys. The popularity of plush fabric dates back to as early as 1903 in the USA, where it emerged as a more affordable and safer substitute for natural bear fur, particularly for beloved Teddy Bear toys.
The Core Manufacturing Process
The creation of plush fabric fundamentally revolves around the formation of its distinctive pile. This is achieved through two main textile manufacturing methods: weaving and knitting.
1. Weaving Process for Plush
In woven plush, the extra yarns forming the pile are integrated into the fabric structure during the weaving process.
- Pile Yarn Insertion: Specialized looms are used where additional warp yarns (pile warp) or weft yarns (pile weft) are introduced alongside the base warp and weft yarns. These pile yarns are looped over wires or rods.
- Cutting the Loops: After the weaving is complete, or sometimes as part of the weaving process itself, the loops are precisely cut. This cutting action creates the open, upright fibers that characterize the plush pile. The length of the loops and the subsequent cut determine the pile's height.
- Examples of Woven Plush: Common examples include velveteen, corduroy, and certain types of upholstery velvet.
2. Knitting Process for Plush
Knitted plush fabrics often offer more stretch and drape, making them suitable for different applications.
- Loop Formation: In knitting, the pile is formed by introducing extra yarns that create loops on the fabric's surface during the knitting sequence. These can be done using warp knitting (e.g., tricot, raschel) or weft knitting (e.g., circular knitting machines).
- Pile Yarn Integration: Special knitting machines are designed to incorporate these extra yarns, creating either a loop pile (where the loops remain intact) or a cut pile (where the loops are subsequently cut).
- Cutting and Shearing: Similar to weaving, if a cut pile is desired, the loops are carefully cut after knitting to release the individual fibers, resulting in a soft, fuzzy surface. Further shearing or brushing may be applied to refine the pile's appearance and texture.
Key Techniques in Pile Formation:
- Wire Method: For woven plush, wires are inserted during weaving, and the pile yarns loop over them. When the wires are removed, the loops are either left intact (loop pile) or cut (cut pile).
- Double Fabric Method: Two fabric layers are woven simultaneously, connected by the pile yarns. A blade then cuts these connecting yarns, separating the two fabrics and creating two separate pieces of plush fabric with cut piles.
- Terry Weave: While primarily used for towels, this is an example of creating a loop pile fabric without cutting, where specific yarns are intentionally left in loops.
Materials Used in Plush Production
Plush fabrics can be made from a variety of fibers, influencing their texture, durability, and cost.
- Polyester: Very common for its softness, durability, and resistance to shrinking and stretching. Often used for synthetic plush toys and blankets.
- Acrylic: Known for its wool-like feel, warmth, and resistance to fading.
- Cotton: Provides a natural, breathable, and absorbent plush, often used for velveteen and corduroy.
- Rayon (Viscose): Offers a luxurious, silken sheen and excellent drape, often blended with other fibers.
- Wool: Though less common for modern "plush" in the synthetic sense, wool pile fabrics (like some historical velvets) offer natural warmth and resilience.
- Blends: Many plush fabrics are made from blends of these fibers to combine desirable characteristics, such as softness with durability.
Properties and Applications of Plush
The unique manufacturing process of plush material imparts several desirable properties:
- Exceptional Softness: The dense, upright pile creates a remarkably soft and comforting tactile experience.
- Warmth: The trapped air within the pile acts as an insulator, making plush fabrics excellent for warmth.
- Luxurious Appearance: The texture and depth of the pile give plush a rich, high-quality look.
- Versatility: Its diverse range of materials and finishes allows for application in various products.
Common Applications:
- Toys: Stuffed animals (like teddy bears), dolls, and novelty items.
- Apparel: Robes, loungewear, jackets, and lining for coats.
- Home Decor: Blankets, throws, pillows, upholstery for furniture, and curtains.
- Automotive: Interior trim and seating covers.
Weaving vs. Knitting for Plush
| Feature | Woven Plush | Knitted Plush |
|---|---|---|
| Structure | Interlaced warp and weft yarns, with pile yarns integrated. | Interconnected loops of yarn, with pile yarns incorporated. |
| Stability | Generally more stable, less stretchable. | More stretchable, conforms to shapes better. |
| Pile Formation | Pile yarns are woven into the base fabric and then cut/left looped. | Pile yarns are looped and attached during the knitting process. |
| Common Uses | Upholstery, formal wear, velveteen, corduroy. | Blankets, loungewear, stuffed toys, lining. |
| Examples | Velvet, Velveteen, Corduroy | Fleece, Faux Fur (often knitted), Minky fabric |
The method chosen for producing plush material depends largely on the desired properties of the final product, including its drape, stretch, durability, and intended use. Both weaving and knitting excel at creating the signature soft, piled surface that defines plush.
