The world of textile manufacturing has evolved rapidly. Today, 3D knitting is no longer just a research concept, but a growing industrial practice that serves fashion, sportswear, medical textiles, and even aerospace. Modern knitting machines, with electronic controls and smart software, make it possible to design and produce complex shapes directly, reducing waste and cutting down on production steps.
Cutting Patterns in 3D Knitted Garments
Cutting patterns of a 3D knitted garment represent the two-dimensional components of clothing. This is still an important part of design and product development. After cutting, the patterns are graded into different sizes. Grading remains a complex task, as it ensures that the final garment will fit different body shapes.
Even in 2025, this process has two key methods:
- Reduction of surplus area – removing extra fabric using darts, seams, folds, or gathers.
- Addition of material – inserting extra fabric where needed.
These methods balance circumferential differences (like chest vs. waist), but with modern 3D knitting, many of these adjustments are directly built into the fabric design, reducing manual labor.
3D Knitting on Flat Knitting Machines
Flat knitting machines remain at the center of 3D knitting innovation. Using needle parking and electronic needle selection, designers can activate or deactivate individual needles to create shaping:
- Extension – increasing active needles.
- Constriction – reducing active needles.
In 2025, modern flat knitting machines come with AI-assisted software that automatically converts 3D garment designs into knitting instructions. This reduces the risk of loop distortion and yarn breakage that older systems faced. The ability to knit complex structures like seamless shoes, ergonomic sportswear, and medical supports has made flat knitting a highly versatile option.
3D Knitting on Small Circular Knitting Machines
Small circular knitting machines (diameter <165 mm) are widely used for socks, bandages, and hosiery. These machines feature a pendulum heel element, which makes it possible to create varying widths. By adjusting sinker height online, manufacturers can shape fabric in real time, giving better control over stretch and fit.
In today’s industry, many small circular machines are fully computerized, allowing on-the-fly loop height variation. This results in better precision for medical compression socks, athletic wear, and seamless fashion items.
3D Knitting on Large Circular Knitting Machines
Large circular knitting machines are mainly used for mass fabric production. Traditional limitations, like the lack of needle parking or pendulum functions, made true 3D knitting impossible. However, in 2025, Jacquard large circular knitting machines are starting to close this gap.
With smart software integration and minor hardware upgrades, Jacquard systems can now produce 3D elements (such as domes or bulges) while keeping the continuous high-speed motion needed for large-scale production. This balance between productivity and design flexibility has made large circular knitting more relevant for 3D garment applications.
Applications of 3D Knitting in 2025
Today, 3D knitted fabrics are not limited to fashion. They are being used in:
- Medical – compression wear, bandages, prosthetic covers.
- Automotive – seat covers, airbags, and interior fabrics.
- Sports – lightweight shoes, ergonomic gear, breathable jerseys.
- Aerospace – advanced textiles for flexible yet durable components.
Bharat Machinery Works – Your Knitting Partner
At Bharat Machinery Works, we provide the latest Flat Knitting Machines and Circular Knitting Machines that support 3D knitting technology. Our machines are globally recognized for their durability, precision, and adaptability to new trends.
We continually update our products with smart controls, electronic needle selection, and AI-driven pattern systems to meet the rising demand for high-tech textiles. Whether you’re producing socks, sportswear, or industrial textiles, our machines deliver performance, efficiency, and innovation.g the design process. Moreover, different knitted structures, i.e. tight and loose patterns are interdependent which results in a “bulge” effect of the entire fabric.
We can also change the dimensions of weft knitted structures by using different machine parameters. Though by varying the dimensions we can add or reduce the volume of the fabric. We have a limited range of variable dimensions which cannot result in the full reduction or addition of the material. To overcome this dilemma, we have developed a pattern which enables the machine to produce the desired dart structure. So, 3D knitting is possible on large jacquard circular knitting machines.
We can manufacture a 3D half dome prototype according to the 3D measurements that we require by using these knitting machines. In future, we can use this technology in various fields such as medical, automotive, the sports textiles as well as the aerospace sectors.