dryforming

Dryforming is a nonwoven fabric manufacturing process that creates a web of fibers without the use of water. This distinguishes it from the more traditional wetlaid process, which uses water as a medium to disperse and form the fiber web. In dryforming, fibers are typically manipulated in a dry state.

Several methods fall under the umbrella of dryforming. Airlaying is a common technique where fibers are dispersed in an airstream and then deposited onto a moving screen or collector. This allows for the creation of uniform webs with a wide range of fiber types and thicknesses. Another approach is carding, which is often used for longer staple fibers. In carding, fibers are drawn through a series of rotating rollers with fine teeth that align and entangle them into a web.

The dryforming process offers several advantages. It generally consumes less energy than wetforming as there is no need for extensive water handling and drying. It also allows for the use of a wider variety of fiber types, including those that may not be compatible with water, such as recycled materials or synthetic fibers. The resulting nonwoven fabrics can be used in a diverse array of applications, including hygiene products, geotextiles, filtration media, and insulation. The specific properties of the dryformed fabric, such as strength, density, and absorbency, can be controlled by adjusting the fiber type, fiber length, and the formation parameters of the chosen dryforming method.