Binder-free & environmentally friendly
No additives are required, making the material recyclable and sustainable.
Functional nonwovens – sustainably bonded
Stability without any additives: Mechanical bonding transforms loose fiber fleece into a resilient flat structure – solely through physical interaction. Whether through needling, water jets, or other processes – the fibers are deliberately intertwined, and permanently joined together.
Mechanical bonding – pure fiber power for strong nonwovens
Mechanical bonding processes are always used when thermal or chemical processes are not possible or desirable – for example, due to sensitive fiber materials or special requirements for the end product. At Freudenberg Performance Materials, we use mechanical bonding specifically to produce structured, robust, and binder-free nonwovens – ideal for technical and industrial applications where material purity, strength, and sustainability are key. Depending on your individual requirements, various process technologies are available, such as needling or hydroentanglement. No additional binders – just clear performance.
Needle punching
Needle punching is a mechanical consolidation process in which a random fiber fleece is stabilized by repeatedly piercing it with thousands of needles with fine barbs. The needles grip the fibers during the upward and downward movement and hook them together in a targeted manner, creating a robust, three-dimensional intertwined fiber composite – without the use of chemical aids. The result is high-performance nonwovens with high mechanical strength, a textile feel, and versatile applications. Freudenberg Performance Materials uses needling specifically where maximum robustness, textile properties, and sustainability are required – whether in construction, mobility, filtration, or for special technical solutions.
Schematic process
During the needling process, barbed needles are inserted vertically through the unbound fleece. The fibers are partially reoriented into the third dimension and intertwined with each other. The needles, which are fixed to a needle board, pierce and exit the unbound fleece, which is guided between two perforated plates. The geometry of the needles, the needle density, the geometry of the needle arrangement in the needle board, and process parameters such as penetration depth and number of stitches per m2 define the product quality. The weight per unit area for needling is usually over 50 g/m2. The system speed is low because the needles remain in the nonwoven fabric for a certain amount of time.
High mechanical strength
Needle-punched nonwovens are particularly resilient, tear-resistant, and abrasion-resistant.
Versatile material compatibility
Suitable for natural fibers, synthetic fibers, or blends – even recycled materials can be processed without any problems.
Controllable volume & structure
Depending on the needle density, type, and depth, both thin and voluminous nonwovens can be produced.
Hydroentanglement
In hydroentanglement, an unbound fiber web is mechanically bonded using fine water jets emitted under high pressure. These water jets penetrate the web and swirl the fibers so intensively that a stable, uniformly structured surface structure is created – without the use of chemical binders. The result is a high degree of bonding. The process requires precise coordination of water pressure, nozzle geometry, fiber type, and nonwoven structure, thereby enabling precise control over feel, strength, and surface appearance. The textile properties of the nonwoven fabric, e.g., softness, are comparable to those of conventionally manufactured textiles (woven fabrics). The basis weights range between 20 and 200 g/m2.
Schematic process
During the process, the unfixed fleece is reoriented in all three dimensions using high-pressure water jets and intertwined. The diameter of the holes from which the water jets emerge is usually 0.1 mm, and the distance between two holes in the nozzle strip is 0.6 mm. Arrangements with single or double rows of nozzle holes are used. Underneath the unbound fleece is a screen base through which the process water passes. This screen base also increases the efficiency of the swirling or consolidation process by partially reflecting the water jets. The process water is filtered and recycled, and the residual water content in the fleece is extracted and dried.
Binder-free & skin-friendly
The consolidation process is purely mechanical, so no chemical binders are used – no adhesives, no additives – making it recyclable and environmentally friendly.
Textile-like softness
Fibers or filaments are matted in all directions using high-frequency water jets – similar to woven textiles.
Uniform strength in all directions
High tear resistance combined with good drapeability, wash resistance, and soft touch.
High design freedom
Wide range of possible applications and finishes such as pattern embossing and printing (e.g., for decorative or functional surfaces) possible.
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If you need textile-like, flexible, soft, or sustainable nonwovens, this mechanical consolidation can can generate the perfect solution for your diverse applications. Take advantage of our technological expertise and get your project started.