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High-Performance Suspension Fabric for Automotive and Furniture Applications

High-Performance Suspension Fabric (Dymetrol) for Automotive and Furniture Applications

Summary

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Acme Mills is once again partnering with a leading Japanese manufacturer of chair materials and automotive seat components to supply Dymetrol® suspension fabrics for their automotive and furniture divisions. The project focuses on meeting the client’s need for innovative seating solutions that provide enhanced comfort, durability, and design efficiency while adhering to strict safety and quality standards.

As an ongoing initiative, this collaboration emphasizes customization, precision manufacturing, and robust quality control measures to support the client’s production processes and align with their delivery timelines.

Project Specifications

Materials: Dymetrol® suspension fabric in various configurations:
C100S: 1040mm and 2080mm widths (Black)
C150S: 1040mm and 2080mm widths (Beige)
C200S: 1040mm and 2080mm widths (Black)
Use Case:
Automotive: Structural seating suspension fabric for automotive seat systems to replace traditional springs and wires.
Furniture: Upholstered seating for office, residential, and public seating applications requiring consistent tension and ergonomic support.

Manufacturing Details

1. Material Preparation

Base Material: 100% woven polyester engineered for varying firmness levels to suit different seating applications.

Customization: Red Hytrel strip integrated at 5-inch intervals for automotive fabric to aid in precise seat assembly alignment.

2. Fabric Production

Weaving Process: High-precision weaving ensures uniform tension, strength, and structural integrity across all fabric rolls.

Dimensional Consistency: Fabrics are produced in specified widths and lengths to minimize material waste and streamline the client’s production process.

3. Roll Slitting and Re-Rolling

Rolls are slit to required widths and re-rolled, with inspections for length accuracy, edge quality, and consistent tension.

Each roll is labeled with essential product details, including serial numbers and manufacturing dates, for seamless inventory management.

4. Packaging and Delivery

Rolls are wrapped and moisture-protected to ensure safe transport.

Documentation, including Certificates of Analysis, flammability test reports, inspection maps, and packing lists, is prepared and sent ahead of shipments.

Quality Control Steps

Incoming Material Inspection

Material Certification: Polyester fibers are tested for tensile strength, elongation, and uniformity before processing.
Dimensional Checks: Initial rolls are verified for compliance with width, thickness, and weight specifications.

In-Process Inspections

Weave Integrity: Continuous visual and mechanical inspections ensure consistent bonding and defect-free production.
Performance Testing: Random samples undergo stress tests to confirm compliance with performance benchmarks.

Final Inspection

Visual and Physical Assessment: Completed rolls are inspected for defects, such as frayed edges or uneven seams.
Label Verification: Each roll is checked for accurate labeling and compliance with packaging requirements.

Project Highlights

Enhanced Seat Construction: The ongoing supply of Dymetrol® fabrics is enabling the client to produce seating solutions that improve comfort and durability while simplifying assembly processes by eliminating traditional seat components such as springs and wires.
Tailored Solutions: Acme Mills has customized fabric dimensions and integrated features, such as Hytrel alignment strips, to meet the client’s automotive and furniture application needs.
Commitment to Quality: Rigorous quality control protocols ensure that each production batch meets or exceeds industry standards for safety, performance, and durability.
Reliable Supply Chain: Acme Mills’ proactive production scheduling and communication help ensure seamless alignment with the client’s ongoing production schedule, with further shipments in preparation.

Next Steps

Production Continuity: Additional production batches are currently in progress to meet future shipment deadlines.
Feedback Integration: Acme Mills continues to collaborate closely with the client to address feedback and adjust material specifications as needed to support evolving project requirements.
Final Shipment Timeline: The final set of deliveries for this phase of the partnership is scheduled for March 2025, with further potential expansions under discussion.

This ongoing project demonstrates Acme Mills’ ability to provide customized, high-performance suspension fabrics that align with client needs across multiple industries. Through close collaboration, precise manufacturing, and rigorous quality assurance, Acme Mills is supporting the client’s production of innovative seating solutions and reinforcing its position as a trusted supplier in competitive manufacturing markets.

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