Specialised production of reinforcement textiles for wind turbine blades

The MULTIPLY BX focuses on the highly efficient production of biaxial non-crimp fabrics for rotor blades. The machine processes glass fibres using a non-course-oriented weft insertion system to produce reinforcement textiles with a high proportion of filler yarns, lightweight weft yarns and long stitch lengths.

These materials are particularly relevant for the predominantly unidirectional reinforcement of wind turbine blades, where high mechanical performance and efficient fibre utilisation are essential.

By concentrating on a specific range of reinforcement structures, KARL MAYER has optimised the machine for the requirements of wind power manufacturers, particularly in growth markets such as China.

“When developing the MULTIPLY BX, we consistently focused on the needs of our wind power customers. The starting point was a special fibre reinforcement fabric; the result is a highly efficient machine in its field. We look forward to presenting it during our Product Show at KARL MAYER (China) during ITMA ASIA 2026 and to a wide-ranging discussion about it,” says Dr. Jürgen Tröltzsch, Product Specialist for Composite Machines, KARL MAYER Technical Textiles.

Up to 25% higher productivity

With operating speeds ranging from 1,600 to 2,200 min⁻¹, depending on stitch length, the MULTIPLY BX achieves a production output of up to 500 m/h. According to KARL MAYER, this represents a productivity increase of 20 to 25% compared with the MAX GLASS ECO, which is already established in the wind power market.

The machine reaches its highest performance at stitch lengths of 4 to 5 mm, typical of reinforcement fabrics used in this application.

Filler yarns with a linear density of up to 2,400 tex are combined with lightweight weft yarns of 100 to 200 tex for transverse stabilisation. This configuration prioritises fibre reinforcement in the longitudinal direction, with a typical weight ratio of filler to weft yarns of 6:1 in the finished fabric.

Technical enhancements improve fabric quality and machine performance

The MULTIPLY BX combines proven components from the MAX GLASS ECO with targeted modifications to increase productivity and improve fabric quality.

The operating concept, selected technological components and basic structure of the laying system have been retained. The main developments concern the weft insertion system and warp knitting zone.

To increase output, the width of the weft carriage has been expanded from 8 inches on the MAX GLASS ECO to 12 inches for parallel weft insertion and 16 inches for cross weft insertion.

In the warp knitting zone, an adjusted needle lift movement reduces the formation of so-called “fish eyes”. These hole-shaped defects occur when knitting needles penetrate the laid fabric and can adversely affect the mechanical properties of the resulting fibre-reinforced semi-finished products.

The lever movement has also been optimised to minimise vibrations during high-speed operation. These modifications are intended to ensure smoother machine operation, reduce wear and improve working conditions for operators.

Increased working width improves material utilisation

The MULTIPLY BX also features an increased working width, from 101 to 103 inches, to better meet the requirements of rotor blade manufacturers.

The additional width enables more efficient material utilisation when producing narrow strips of reinforcement fabric, which are subsequently cut and processed for wind turbine blade manufacturing.

By combining higher production speeds with application-specific material efficiency, the MULTIPLY BX is designed to support cost-effective manufacturing of high-performance reinforcement textiles for the wind energy sector.

Live demonstration at KARL MAYER (China)

The MULTIPLY BX will be demonstrated during the KARL MAYER (China) Product Show in Changzhou on 19–21 November and 23 November 2026, coinciding with ITMA ASIA 2026.