Regarding the actual weaving performance, the mechanical aspects of the weaving process were excellent in the sense that no warp yarn breakage or failure occurred during the entire production of 150 yards of fabrics of different configurations. However, the fabric quality was not satisfactory. Noticeable pill-like, minor defects were formed on the fabric surface, which is objectionable. These fuzzy defects, as shown in Figure 3, most likely were caused by abrasion and, hence, disintegration of the warp yarns in the reed-sweep zone. Visual inspections of the fabrics showed that although some areas of the fabrics had almost negligible defects (see Figure 4), the most areas had highly significant number of those defects, which made the total fabric of unacceptable quality. Multi-directional efforts to determine the underlying cause (s) of these defects and explore possible remedies are continuing. The yarn structure, (size-less) topical treatments, specially coated loom components (especially, the reed); and weaving parameters are the primary items in the current focus.

Based on the preliminary results and observations of the size-less weaving trial conducted, it seemed that the optimum pick density (i.e., fabric construction) that could be efficiently woven, at the weaving machines commercial running speed of 500 ppm, was 40 ppi. Beyond this pick density, the weaving performance (mainly the fabric quality) at the above referenced loom speed deteriorated considerably. Even at 400 ppm, the 50 ppi density produced unsatisfactory fabric quality. In fact, a pick density greater than 50 ppi invariably produced unsatisfactory weaving results and fabric quality. However, it appeared though that the weaving speed was not as critical as the pick density. With an attainable pick density, the weaving speed did not appear to make a significant difference in the weaving performance or fabric quality. Relatively higher weaving speeds may even be attainable for relatively lower pick densities (i.e., for lighter-than-standard fabric constructions such as a medical guaze).