Variation Braiding: from 4x4 to 6x6 – new application potential through more complex 3D braiding structures

Frank Ficker; Roxana Miksch; Karline Grosser; Recep Kocaman; Corinna Anzer

doi:10.25367/cdatp.2026.7.p23-32

Authors

Frank Ficker Institute for Materials Science (ifm), Hof University of Applied Sciences, Germany https://orcid.org/0000-0002-7166-3640
Roxana Miksch Institute for Materials Science (ifm), Hof University of Applied Sciences, Germany
Karline Grosser Institute for Materials Science (ifm), Hof University of Applied Sciences, Germany
Recep Kocaman Institute for Materials Science (ifm), Hof University of Applied Sciences, Germany https://orcid.org/0000-0002-9174-1597
Corinna Anzer Institute for Materials Science (ifm), Hof University of Applied Sciences, Germany

DOI:

https://doi.org/10.25367/cdatp.2026.7.p23-32

Keywords:

braiding, variation braiding, bifurcation, 3d braiding, square matrix

Abstract

In this article, new possibilities about the patterning on a variational braider with 6x6 horn gears are presented. Various types of braided structures, such as bifurcation braids, knotless nets or textile chain elements were developed using braiding pattern techniques and were manufactured on braiding machines with a wide range of materials (synthetic fibers, carbon fibers, glass fibers, ceramic fibers, natural fibers). Additionally, by using the new 6x6 variation braider, the existing patterns and products of the 4x4 braiding machine are being optimized and expanded.

References

[1] Becker, M.; Ficker, F.; Miksch, R. Variation braiding technology by the example of novel stent structures. The 22nd International Conference Strutex 2018.

[2] Becker, M. Braiding Technology Based Stent Concept for Endoluminal Usage in Coronary Bifurcations. 2018. https://contest.techbriefs.com/2018/entries/medical/8691-0425-084538-braiding-technology-based-stent-concept-for-endoluminal-usage-in-coronary-bifurcations.

[3] Kocaman, R. T.; Großer, K.; Ficker, F. Innovative single and bifurcated coronary stents: from braiding to flexibility: Łódź University of Technology Press; 2022.

[4] Becker, M.; Ficker, F.; Schon, D. Load-specific fiber reinforcements for aerospace applications made of inorganic fibers. Aeronautics and Aerospace Open Access Journal 2019, 3, 120-122.

[5] Fehrenz, S.; Athmann, M.; Gemeinholzer, B.; Pecenka, R.; Silbermann, S.; Klussmann, H. SALIX – Breeding Willows with Specific Material and Growth Characteristics for Textile Timber Construction and as a Source of Salicylates. In: Scalable Disruptors: Design Modelling Symposium Kassel 2024, 1st ed.; Eversmann, P.; Gengnagel, C.; Lienhard, J.; Ramsgaard Thomsen, M.; Wurm. J., Eds.; Springer Nature: Cham, Switzerland, 2024, pp. 307-319.

[6] Textiltechnik als Schlüsseltechnologie der Zukunft. 17. Chemnitzer Textiltechnik-Tagung, CTT 2022: Technisches Radialflechten von Massivholzstrukturen: Förderverein Cetex Chemnitzer Textilmaschinenentwicklung; 2022.

[7] Li. X.; He, X.; Liang, J.; Song, Y.; Zhang, L.; Wang, B.; et al. Research Status of 3D Braiding Technology. Appl. Compos. Mater. 2022, 29, 147-157.

[8] Zhou, Z.; Sun, Z.; Shan, Z.; Guo, K.; Yang, T.; Yang, H.; et al. Advanced composite preform forming technology for structures and its digitization: A review. Thin-Walled Structures 2025, 211, 113053.

[9] Kyosev, Y. Braiding technology for textiles. Woodhead Publishing in association with the Textile Institute: Cambridge, 2015.

[10] Bogdanovich, A. E.; Mungalov, D. Recent advancements in manufacturing 3-D braided preforms and composites. Proceedings of ACUN-4 — Composite Systems: Macro Composites, Micro Composites, Nanocomposites, University of New South Wales (UNSW). Sydney, Australia, 21–25 July 2002; pp. 61-72.

[11] August Herzog Maschinenfabrik GmbH & Co. KG. Variation Braiding Machine Type VF_1_4-32-140. https://herzog-online.com/.

[12] Berger, H. Apparatus for braiding knotless netting. Patent US3866512, USA, 1975.

[13] Schreiber, F. Three-dimensional hexagonal braiding. In Advances in braiding technology: Specialized techniques and applications; Elsevier/WP Woodhead Publishing: Amsterdam, Boston, Cambridge, Manchester, 2016; pp. 79-88.

[14] Schreiber, F.; Ko, F. K.; Hee-Jae, Y.; et al. NOVEL THREE-DIMENSIONAL BRAIDING APPROACH AND ITS PRODUCTS. IOM Communications, 2009.

[15] Ko, F. K.; Pastore, C. M.; Head, A. A. Atkins & Pearce Handbook of Industrial Braiding; Atkings & Pearce, 1989.

[16] Douglass, W. Braiding and braiding machinery. N.V. Uitgevesmaatschappij Centrex, 1964.

[17] Lepperhoff, B. Die Flechterei. Leipzig, 1914.

[18] Engels, H. Handbuch der Schmaltextilien: die Flechttechnologie. Teil II: Maschinen und Verfahren zur Erzeugung von Flechtprodukten mit speziellen physikalischen und chemischen Anforderungen. Fachhochschule Niederrhein: Mönchengladbach, 1994.

[19] Lengersdorf, M.; Gries, T. Three-dimensional maypole braiding. In Advances in braiding technology: Specialized techniques and applications. Elsevier/WP Woodhead Publishing: Amsterdam, Boston, Cambridge, Manchester, 2016; pp. 89-105.

[20] Herzog CAB Software 2.0 Introduction. Available online: https://www.youtube.com/watch?v=YZ9pP9P-Euc (accessed 18 Feb 2026).

[21] TexMind. Available online: https://www.texmind.com/wp/doku.php?id=start (accessed on 18 Feb 2026).

[22] Glessner, P.; Kyosev, Y. Possibilities for the production and method in the development of lace braiding on 3D braiding machines with continuous rotating horn gears and programmable switches. Textile Research Journal 2025, online first. DOI: 10.1177/00405175251380816.

[23] Krauskopf, J. E.; Rauh, A.; Hein, A. A novel method for listing all collision-free carrier arrangements of maypole braiding machines. Journal of Industrial Textiles 2025, 55, 15280837251371994.

[24] Singh, M.; Fuenmayor, E.; Hinchy, E.; Qiao, Y.; Murray, N.; Devine, D. Digital Twin: Origin to Future. Applied System Innovation 2021, 4, 36.

[25] Kyosev, Y.; Gleßner, P. Extended horn gears in 3D maypole braiding: Theoretical analysis, gear arrangement and prediction of the floating length. J. Text. Fibr. Mater. 2018, 1, 2515221118786741.

[26] Du, C. J.; Zhuo, M.; Yujing, Z.; Yize, S. Modeling and analysis of the carrier arrangement in square rotary braiding. Textile Research Journal 2019, 89, 4208-4219.

[27] Carey, J. P., ed. Handbook of Advances in Braided Composite Materials: Theory, Production, Testing and Applications. Elsevier Science: Kent, 2016.

[28] Kyosev, Y., ed. Advances in braiding technology: Specialized techniques and applications. Elsevier/WP Woodhead Publishing: Amsterdam, Boston, Cambridge, Manchester, 2016.

[29] Miksch, R.; Ficker, F. Multi Bifurcation Branch Braided Structures on a Herzog Variation Braiding Machine. In: Recent developments in braiding and narrow weaving; Kyosev, Y., ed. Springer: Cham, 2016; pp. 15-20.

[30] Becker, M.; Ficker. F.; Miksch, R.; Olbrich, S. Custom-Made Reinforcement Structures Made of Inorganic Fibers Challenges, Chances and Technical Approaches. Key Engineering Materials 2019, 809, 167-170.

[31] Ficker, F. Komplexe Geflechtstrukturen für Luft-, Raumfahrt und Medizintechnik. Melliand Textilberichte 2018, 99, 145.

[32] Ficker, F.; Kocaman, R. T.; Miksch, R.; Anzer, C.; Luft, A. Verzweigte Nitinol-Stents mit lochfreiem Zwickel flechten. 2021. Available online: https://medizin-und-technik.industrie.de/technik/forschung/verzweigte-nitinol-stents-mit-lochfreiem-zwickel-flechten/

[33] Kocaman, R. T.; Miksch, R.; Anzer, C.; Großer, K.; Ficker, F. Innovative verzweigte Koronarstents für die Behandlung koronarer Bifurkationsläsionen. Melliand Textilberichte 2022, 103, 65-68.

[34] TYCAN chains with Dyneema replace steel chains for lashing cargo. Available online: https://www.innovationintextiles.com/industrial/tycan-chains-with-dyneema-replace-steel-chains-for-lashing-cargo/.

[35] Ficker, F.; Miksch, R. Braided structure, in particular stents, and method for braiding a braided structure. Patent US20210113357A1.