11. Open Source Hardware - From Fibers to Fabric¶
Tufting¶
Tufting is a type of textile manufacturing in which a thread is inserted on a primary base. It is an ancient technique for making warm garments, especially mittens. After the knitting is complete, short U-shaped loops of extra yarn are introduced through the fabric from the outside, with their ends pointing inwards.
Tufting gun¶
A tufting gun is a tool commonly used to automate the tufting process, specifically in rug making. The yarn is fed through a hollow needle that penetrates the stretched cloth backing for a modifiable length.
They can usually create two types of rugs: cut or loop-pile.
A cut pile rug's yarn is snipped every other loop into the backing, creating a “U” shape from the side profile, while a loop pile rug isn't snipped and creates a continuous “M” or “W”.Tufting guns are useful tools for both mass production and home use due to their flexibility in scale and color variation.
Image: [By Auckland Museum, CC BY 4.0,] (https://commons.wikimedia.org/w/index.php?curid=83070426)
By Auckland Museum, CC BY 4.0, https://commons.wikimedia.org/w/index.php?curid=83070426
Tufting gun buyer’s guide: Best tufting machines and what you need to know by tinyworkshop
At Greenfabric we have two king of tufting guns.
Dismantling the cut¶
Look at the excellent Claire 's documentation
SAFETY ADVICE Unplug your tufting gun before dismantling it!
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Dismantling of the handle and the guide by unscrewing with the Alen keys the 4 screws around the needle.
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Set aside all your parts in a recipent.
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Release the squealer door by removing the bolts and two square trings.
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Slide the knife holder
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Important: do not disassemble the rod attached to the large gear, do not start the machine!
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With a TORK tip (star) or other suitable tools, remove the screw that holds the knife in the guide.
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Replace the front handle.
Adjust the knife holder.
Screw back the 2 square spacers and the bolt to attach the knife holder to the large wheel. Only then can you reconnect your machine.
We have found that the knife holder is indismensible to security because it is also linked to the ON/OFF button.
Now your tufting gun can be hacked. (not on the picture)
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ATTENTION: This model is different from Claire and Carmen; only the knife needs to be removed. Do not work without the knife holder connected to the gear. Very dangerous!
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Researches¶
First try¶
- Focus on my Tufting gun with this knife holder. The needle cat is very close to the knife holder.
Our reflexion was, if it's suitable for this special tufting fun it will be suitable for all of them.
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Imprint of the needle and the knife holder in modelling clay. This gives us an idea of the profile to adopt.
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At first we imagined a volume that would be screwed onto the needle. A small pick would be adjusted on the cat of the needle.
The left drawing is a cut at the cat level of the needle and the right drawing is a cross-section that shows where the needles are placed.
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In this measured cut (measurements taken with a caliper), we hollowed out the place of the knife holder.
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Prototype part made with Scktechup and printed in PLA on our PRUSA mini.
The parts fit perfectly on our tuftinn.
Second try¶
Following this first attempt, Carmen and each other tried their technique with modelling clay and cardboard. These machines are powerful, and the small peak should be highly sought after. The peak is too fragile.
This experience has reoriented all our research.
An element printed in FLEW has been adapted to introduce the tufting gun needle. The filling of the 3D printed part has been lightened to improve the flexibility of the part.
This part is not (yet) adapted to my tufting gun model with the knife holder.
Results¶
In these photos, you can see : The transparent FLEX part penetrates, which is inserted into the PLA tube, and screwed through the needle barrel.
A thread allows the adaptation of commercially available needle holders with mini spun rods.
A manual needle holder has been designed to choose the pattern of its needles. A handle can be screwed for manual use.
A final adaptation is necessary to adapt this needle holder to the tip of the tufting gun.
Images and drawings: Annabel Fournier unless otherwise stated