The use of thermoplastic components with a complex three-dimensional (3D) shape, manufactured efficiently with thermo-presses, has been increased steadily. Flat knitting technology using reinforcing hybrid yarns in the horizontal and vertical direction is especially suited for producing near-net-shape or fully-fashion multilayer weft knitted fabrics – MLGs (abbreviated from the German word Mehrlagengestrick, meaning multilayer weft knitted fabric). The other advantages of manufacturing such MLGs, using flat knitting technology, are reduced waste and desired reinforcing fibre alignment to obtain improved mechanical properties for high-performance applications. Before knitting 3D shaped MLGs, it is necessary to transfer the 3D component geometry into a suitable two-dimensional (2D) pattern cut by implementing parting lines. The use of computer-aided design (CAD) programs enables an effective development of complex components preforms. The generated 2D pattern cuts are analyzed with the consideration of net-shape preforming processes on V-bed flat knitting machines. The development of a segmented take-down system for effective production of 3D MLG preforms is also discussed.

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