Felt - What is it?
We actually take it a step further than regular felt. At G-Desmet, we use PET felt. This is a versatile material made from recycled PET, such as plastic bottles. The production process of felt begins with converting the PET material into very small pellets. These pellets are then spun into long and extremely thin threads. These threads are then woven using a type of machine that contains thousands of barbed needles. This step is also known as needle punching. The fibers are essentially compressed by the machine. This creates the final material we need: felt mats ready for processing, also known as non-woven felt.
The above process takes place at our reliable suppliers. They ensure that we can focus on our specialty, which is shaping. They provide us with large rolls of felt, and we supply the necessary creativity.
Thanks to its endless versatility and strength, felt is the ideal and sustainable solution for designers, product managers, etc., who like to see their ideas processed into hundreds of pieces immediately. Felt is the future. Think of chairs, acoustic walls, and even storage baskets. The sky is the limit. Did you also know that felt is available in various colors? We can perfectly tailor everything to your wishes
the production process at g-desmet
Okay. You now have an idea of what 'felt' is. But how do we come to creative designs? We'll take you through it step by step.
1. dELIVERY OF THE FELT mats
The felt mats are delivered in large rolls. The rolls are also available in different colors. The available colors? You can read about them in our previous blog, Custom Colour Collection.
2. Cutting the felt
Of course, the rolls need to be cut. We do this precisely with our machines. The machines are equipped with sharp and rotating blades that cut the felt without damaging the fibers. Clean and straight edges are essential for the entire production process to achieve a perfect end result. Precision is crucial to minimize 'waste'. Correct, 'waste' is in quotes because nothing is truly considered 'waste' with us. The pieces that are cut off can be reused within the production process. It is a cycle that repeats itself.
3. Heating in the oven
Next, the cut mats are heated in a large oven. The heating process makes the felt flexible, allowing it to be prepared for shaping in the next step. Multiple mats can be heated in the oven at once, depending on the size of the pieces. This all takes place at high temperatures and within just a few minutes. A quick and efficient process is guaranteed.
4. creating the shape
After a few minutes, the heated felt is ready to be shaped. We place it in our so-called molds. Here, the felt is pressed into shape. The aluminum molds can be seen as templates or models in which the material is placed. They are specially designed by us to ensure the felt gets the right shape. Chairs, walls, pots... your idea in our hands. The mat remains in its shape until it has sufficiently cooled. How long? That depends on the thickness and size of the desired shape. An average time is about 5 minutes.
5. waterjet cutting
Then comes the final step. Once the felt has cooled - and thus also formed - there are still some pieces of felt that are redundant in the design. These are cut using our waterjet cutting machine. This is an advanced cutting technology that uses a powerful jet of water to cut the felt. The machine offers extraordinary precision, without deforming the material. All this in just a few minutes. Meanwhile, our second waterjet cutting machine has been installed.
So, now you have a simple glimpse of our felt production process. A process where precision, craftsmanship, and innovation come together. We are experts in our field.
Want to know more about this process? Or perhaps curious about what we can do for your idea? We are happy to help you. Contact us at https://www.g-desmet.be/en/contact-g-desmet. Hope to see you soon?
