<?xml version="1.0" encoding="UTF-8"?><!DOCTYPE article  PUBLIC "-//NLM//DTD Journal Publishing DTD v3.0 20080202//EN" "http://dtd.nlm.nih.gov/publishing/3.0/journalpublishing3.dtd"><article xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink" dtd-version="3.0" xml:lang="en" article-type="research article"><front><journal-meta><journal-id journal-id-type="publisher-id">JTST</journal-id><journal-title-group><journal-title>Journal of Textile Science and Technology</journal-title></journal-title-group><issn pub-type="epub">2379-1543</issn><publisher><publisher-name>Scientific Research Publishing</publisher-name></publisher></journal-meta><article-meta><article-id pub-id-type="doi">10.4236/jtst.2023.93012</article-id><article-id pub-id-type="publisher-id">JTST-127195</article-id><article-categories><subj-group subj-group-type="heading"><subject>Articles</subject></subj-group><subj-group subj-group-type="Discipline-v2"><subject>Chemistry&amp;Materials Science</subject></subj-group></article-categories><title-group><article-title>
 
 
  An Overview of 3D Thin Shell Textile Preforms
 
</article-title></title-group><contrib-group><contrib contrib-type="author" xlink:type="simple"><name name-style="western"><surname>Mohammad</surname><given-names>Toufiqul Hoque</given-names></name><xref ref-type="aff" rid="aff1"><sub>1</sub></xref><xref ref-type="corresp" rid="cor1"><sup>*</sup></xref></contrib></contrib-group><aff id="aff1"><label>1</label><addr-line>Department of Textile and Clothing Technology, Hochschule Niederrhein, University of Applied Sciences, M&amp;amp;ouml;nchengladbach, Germany</addr-line></aff><pub-date pub-type="epub"><day>03</day><month>07</month><year>2023</year></pub-date><volume>09</volume><issue>03</issue><fpage>183</fpage><lpage>197</lpage><history><date date-type="received"><day>1,</day>	<month>June</month>	<year>2023</year></date><date date-type="rev-recd"><day>21,</day>	<month>August</month>	<year>2023</year>	</date><date date-type="accepted"><day>24,</day>	<month>August</month>	<year>2023</year></date></history><permissions><copyright-statement>&#169; Copyright  2014 by authors and Scientific Research Publishing Inc. </copyright-statement><copyright-year>2014</copyright-year><license><license-p>This work is licensed under the Creative Commons Attribution International License (CC BY). http://creativecommons.org/licenses/by/4.0/</license-p></license></permissions><abstract><p>
 
 
  The automobiles, aircraft, and lightweight industries continuously demand thin near-net-shape preforms just out-of-machine as close to the final shape. This study addresses the possibilities of 3D thin shell textile preform as the solution of lightweight reinforcement in various applications. Investigation into the development of 3D thin shells has led to different manufacturing processes. However, 3D thin shell preforms are mostly made by weaving and 
  knitting, but nonwoven, winding, and/or layup techniques have been reported for over a decade. Owing to the complex thin shell manufacturing processes, they are not similar to the conventional methods. The different 3D thin shell preforms can extend the opportunities for new applications in various technical fields. This study presents existing research gaps and a few potential issues to be solved regarding 3D thin shell preforms in the near future.
 
</p></abstract><kwd-group><kwd>3D Thin Shell Preform</kwd><kwd> Weaving</kwd><kwd> Knitting</kwd><kwd> Braiding</kwd><kwd> Nonwoven</kwd><kwd> Winding and/or Layup</kwd></kwd-group></article-meta></front><body><sec id="s1"><title>1. Introduction</title><p>The utilization of thin shells for technical applications has been on the rise, especially as composites for engineering purposes. Textile composites can provide performance benefits, particularly in terms of high-strength ratios compared to metal counterparts, which make them suitable for automotive and aerospace industries, where reduced weight contributes to fuel efficiency and notably improves ease in handling in the manufacturing processes. The development of 3D thick textile preforms has increased over the past few decades [<xref ref-type="bibr" rid="scirp.127195-ref1">1</xref>] . Textile engineers are challenged to introduce lighter technical parts as composites. Therefore, 3D thin shell preforms hold great promise for automotive, aerospace, and other engineering applications.</p><p>More than one hundred years ago, people started to develop 3D textiles for technical applications. Due to their diverse fields of applications, the demands of 3D thin shell textile preforms besides the thick components in the fast-growing area of modern composite materials for different commercial industries are immense [<xref ref-type="bibr" rid="scirp.127195-ref1">1</xref>] . However, until today, there is no addressable definition for thin shell textile preforms. Unfortunately, there are not enough profound breakthroughs yet to imply and extend the use and value of 3D thin shells for industrial and engineering applications, which essentially require the shaping ability to maintain strength and automation. An understanding of shape geometry for design, process optimization, and production methods for 3D thin shells is still missing.</p><p>Besides, the conventional and existing techniques, design complexity, and product scalability are challenged in the progress of manufacturing. The production of 3D thin shells directly by a manufacturing process without the support of seaming, molding, or deep drawing is a challenge for researchers, which still needs precision to maneuver thin shells into the correct shape. However, different fabric manufacturing techniques are used to produce 3D thin shell preforms, which contain thickness limitations, and shape-wise irregularities. This paper addresses a few key manufacturing processes of 3D thin shells and provides an understanding of their scopes and application areas with important examples. This study also sheds light on the industrial requirements of thin shells and gaps to optimize production.</p><p>3D thin shell textile preform can be referred to as near-net-shape with a substantial diameter and shows interpolated curvature due to possible slippage between fibers, and displacement in the thickness direction. Thin shells can be regarded as shells having a much lower thickness in comparison to width and length (thickness &lt;&lt; length, width) and a shell preform has a three-dimensional shape known as near-net-shape. For example, a helmet is a thin shell preform, exhibiting both 3D and near-net-shape of predefined thickness. However, 3D-spacer preforms are not thin shells, as they do not match near-net-shape criteria. Hu defined 3D contoured preforms, which are fully integrated fibrous (continuous) assemblies containing multiaxial in-plane and out-of-plane fiber orientation [<xref ref-type="bibr" rid="scirp.127195-ref2">2</xref>] . According to Bogdanovich, a 3D textile preform can be termed ‘thin’ when its length and width are measured in tens of centimeters or meters, but the same preform becomes thick when its length and width are measured in millimeters or a few centimeters [<xref ref-type="bibr" rid="scirp.127195-ref3">3</xref>] .</p><p>Thickness plays a crucial role in many industrial and technical applications. Noticeably, research works have been reported on 3D textile components, which are not concentrated on 3D thin shells. Textile composites are used in automotive and other industries due to their intrinsic advantages over metal parts. Unfortunately, there are not many specialized devices and methods to make 3D thin shell textile preforms. On many occasions, fabric-manufacturing techniques have been followed to produce 3D shells. However, only a few automated methods are available to produce such preforms, mainly due to their requirements like fiber materials (carbon, glass, etc.) and deformation capabilities. The demand for lightweight automotive components is on the rise and it is correlated with the overall weight reduction of the vehicle [<xref ref-type="bibr" rid="scirp.127195-ref4">4</xref>] . Nonetheless, the manufacturing of 3D thin shell textile preforms is critical due to quality and seam-free creation. Processes like tailoring, deep drawing, and molding are limited by their poor reproducibility and adverse effect on shape forming. All those reasons are relevant to describe 3D thin shell textile preforms with their applications and opportunities.</p></sec><sec id="s2"><title>2. Thin Shell Manufacturing Techniques</title><p>Different fabric manufacturing processes like weaving, knitting, nonwoven, winding, and/or layup are used to produce 3D thin shell textile preforms. All these techniques can create different 3D structures as presented in <xref ref-type="table" rid="table1">Table 1</xref>. This paper mentions briefly a few important technologies that create 3D thin shell preform and provides an understanding of such complex procedures with different shape possibilities. The 3D braiding technology has a unique ability to form 3D-shaped complex fiber structures integrally [<xref ref-type="bibr" rid="scirp.127195-ref5">5</xref>] , but unfortunately, a 3D thin shell is not possible to generate with this method (<xref ref-type="table" rid="table1">Table 1</xref>).</p><table-wrap id="table1" ><label><xref ref-type="table" rid="table1">Table 1</xref></label><caption><title> 3-D shape manufacturing methods and their types of structures</title></caption><table><tbody><thead><tr><th align="center" valign="middle"  rowspan="2"  >Method</th><th align="center" valign="middle"  colspan="4"  >Type</th></tr></thead><tr><td align="center" valign="middle" >solid</td><td align="center" valign="middle" >hollow</td><td align="center" valign="middle" >shell</td><td align="center" valign="middle" >nodal</td></tr><tr><td align="center" valign="middle" >3D weaving</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >yes</td></tr><tr><td align="center" valign="middle" >3D knitting</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >no</td></tr><tr><td align="center" valign="middle" >3D braiding</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >no</td><td align="center" valign="middle" >yes</td></tr><tr><td align="center" valign="middle" >3D nonwoven</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >no</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >no</td></tr><tr><td align="center" valign="middle" >3D winding and/or layup</td><td align="center" valign="middle" >no</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >yes</td><td align="center" valign="middle" >no</td></tr></tbody></table></table-wrap><p>Here, the nodal is referred to as a truss configuration containing strut members (in hollow or solid forms) which can be joined and/or bonded to form a node [<xref ref-type="bibr" rid="scirp.127195-ref6">6</xref>] .</p><sec id="s2_1"><title>2.1. Woven 3D Shells</title><p>3D weaving is signified as a multiple-weaving method. Langer attempted to make a woven shell out of loom using a simple principle in the early part of the nineteenth century [<xref ref-type="bibr" rid="scirp.127195-ref7">7</xref>] . However, until today, there has been a lack of automated processes and machines for 3D-shaped shells [<xref ref-type="bibr" rid="scirp.127195-ref8">8</xref>] . In modern days, Computer-Aided Design (CAD) and various simulation programs have broadened new avenues for 3D shell manufacturing techniques. Buesgen introduced a revolutionary shape weaving to make 3D woven thin shells using Jacquard weaving [<xref ref-type="bibr" rid="scirp.127195-ref9">9</xref>] . The main idea of shape weaving is to create a fabric area having a larger spacing of weft and warp-ends than in the encircling fabric, which is achieved by mechanical devices and weave design. Shape weaving offers a programmable take-up mechanism to realize varying take-up lengths individually, which enables weft spacing variation. A Jacquard head is placed to execute shedding according to geometry requirements. The overall elements can be controlled by basic hard- and software for machine operation. <xref ref-type="fig" rid="fig1">Figure 1</xref>(a) shows a part of the loom used for shape weaving and <xref ref-type="fig" rid="fig1">Figure 1</xref>(b) illustrates a contoured shell produced by it [<xref ref-type="bibr" rid="scirp.127195-ref9">9</xref>] .</p><p>Loom is the pioneer of all weaving methods for 3D woven structures and shells. Greenwood patented a weaving loom to assist in making woven shells [<xref ref-type="bibr" rid="scirp.127195-ref10">10</xref>] and in the same year, Fukuta et al. showed a method and loom to make woven shells [<xref ref-type="bibr" rid="scirp.127195-ref11">11</xref>] . Talavasek and Svaty introduced a shuttle-less weaving machine [<xref ref-type="bibr" rid="scirp.127195-ref12">12</xref>] , and Krauland Jr. presented a method and apparatus for continuous woven structures [<xref ref-type="bibr" rid="scirp.127195-ref13">13</xref>] . The year 1991 to 2001 was the revolutionary period of making multilayered woven 3D structures, either as woven reinforcements for composites or woven 3D shells for automotive parts [<xref ref-type="bibr" rid="scirp.127195-ref14">14</xref>] - [<xref ref-type="bibr" rid="scirp.127195-ref25">25</xref>] .</p><p>Chen and Tayyar employed an add-on device (easy-to-use) to the conventional loom for making woven 3D shells [<xref ref-type="bibr" rid="scirp.127195-ref26">26</xref>] . They made changes in the let-off mechanism and used a profiled take-up roller. When the add-on device is removed, the loom resumes its original setup for making 2D shapes. Bhattacharya and Koranne introduced a novel method for 3D-shaped woven structures, but those are not of shell types [<xref ref-type="bibr" rid="scirp.127195-ref27">27</xref>] .</p><p>Chen et al. addressed different weaving techniques for 3D-shaped shells [<xref ref-type="bibr" rid="scirp.127195-ref28">28</xref>] . Jetavat showed a near-net-shape structure by 3D weaving [<xref ref-type="bibr" rid="scirp.127195-ref29">29</xref>] . Khokar demonstrated a method and apparatus to produce woven 3D profiles, which are primarily not shell structures [<xref ref-type="bibr" rid="scirp.127195-ref30">30</xref>] . Lu et al. described a novel Origami method to make a 3D woven box [<xref ref-type="bibr" rid="scirp.127195-ref31">31</xref>] . L&#252;ling and Boussu et al. explained a few techniques to create 3D-shaped structures and their applications in their publications [<xref ref-type="bibr" rid="scirp.127195-ref32">32</xref>] [<xref ref-type="bibr" rid="scirp.127195-ref33">33</xref>] . A Ph.D. candidate at Technical University Dresden (Germany) made complex 3D shells <xref ref-type="fig" rid="fig2">Figure 2</xref>(a) using Jacquard technology and won the AVK-Innovation Prize 2022 [<xref ref-type="bibr" rid="scirp.127195-ref34">34</xref>] . Harvey et al. made a woven shoe <xref ref-type="fig" rid="fig2">Figure 2</xref>(b) by realizing different samples of experimental 3D woven structures [<xref ref-type="bibr" rid="scirp.127195-ref35">35</xref>] . They divided the warp into three distinct zones for design: sole, insole, and upper. They planted materials and yarns of varied sizes to emphasize the shoe’s center and bulk up the heel of the shoe so that different sizes of weft were possible to insert. They took the benefits of Jacquard weaving to finalize the traditional shoe components as part of their visual design. They employed the Weavecraft software to design 3D weaves effectively as it contains three easy-to-use windows that collectively provide the information. The task of the software is to generate a standard 2D binary file to run the Jacquard process, which converts into JC file language to run the loom [<xref ref-type="bibr" rid="scirp.127195-ref35">35</xref>] .</p></sec><sec id="s2_2"><title>2.2. 3D Knitted Shells</title><p>Thin shell preforms made by knitting technology represent a group of materials with great flexibility mainly due to the advantage of having fewer process steps. Flat knitting machines are mostly used for their design variability and it offers a versatile way to produce complex 3D-shaped shells, spacers, tubes, and other forms [<xref ref-type="bibr" rid="scirp.127195-ref36">36</xref>] . New software design, performance modeling, and new-generation machines capable of producing complex structures can stimulate the development of 3D-knitted preforms [<xref ref-type="bibr" rid="scirp.127195-ref37">37</xref>] .</p><p>The technologies from SHIMA SEIKI and STOLL have undertaken many important developments. Ciobanu produced a knitted shell <xref ref-type="fig" rid="fig3">Figure 3</xref>(a) using STOLL (CMS 320 TC) knitting technology and described it [<xref ref-type="bibr" rid="scirp.127195-ref37">37</xref>] . Dome-like structures with minimal or no seams can be produced by suspended stitches <xref ref-type="fig" rid="fig3">Figure 3</xref>(b) through WholeGarment<sup>&#174;</sup>, referred to as WG technology from SHIMA SEIKI [<xref ref-type="bibr" rid="scirp.127195-ref38">38</xref>] . The way of producing 3D knitted shells by suspended stitches using SHIMA SEIKI technology is also called the Spickel process.</p><p>There has been a lack of consistency in the lifetime of a car seat for a long time and woven 3D shell dominates automotive sectors. However, SHIMA SEIKI launched an anatomically contoured seat <xref ref-type="fig" rid="fig4">Figure 4</xref>(a) in cooperation with two German companies Trevira and imat-uve [<xref ref-type="bibr" rid="scirp.127195-ref39">39</xref>] . SHIMA SEIKI showed a prototype of a multiaxial knitting machine at Techtextil Fair (Frankfurt, Germany), which can create 3D-shaped shells as shown in <xref ref-type="fig" rid="fig4">Figure 4</xref>(b) and <xref ref-type="fig" rid="fig4">Figure 4</xref>(c) [<xref ref-type="bibr" rid="scirp.127195-ref40">40</xref>] . Simonis et al. made 3D-shaped knitted shells using a large circular knitting machine <xref ref-type="fig" rid="fig5">Figure 5</xref>, where needle parking or pendulum function was not followed due to the discontinuous movement, and continuous movement was maintained throughout the process [<xref ref-type="bibr" rid="scirp.127195-ref41">41</xref>] . Some key innovations for knitted shells were revealed at ITMA 2019 [<xref ref-type="bibr" rid="scirp.127195-ref42">42</xref>] .</p></sec><sec id="s2_3"><title>2.3. 3D Nonwoven Shells</title><p>The nonwoven process to make a 3D thin shell preform is unlike 3D weaving and 3D knitting. However, this process is shorter, faster, and more economical compared with other traditional ones [<xref ref-type="bibr" rid="scirp.127195-ref43">43</xref>] . The maiden 3D nonwoven shell is arguably the felted hat [<xref ref-type="bibr" rid="scirp.127195-ref43">43</xref>] . Felting is an easy process to realize and make 3D-shape manually, but the main drawback is productivity. The German company—Freudenberg Performance Materials developed nonwoven-based Lutraflor<sup>&#174;</sup> technology for automotive interior parts <xref ref-type="fig" rid="fig6">Figure 6</xref>(a) with excellent formability [<xref ref-type="bibr" rid="scirp.127195-ref44">44</xref>] . Air-laying nonwoven process is also an option to produce thin shells; the University of Manchester used a thermal-through air bonding system to make a softer shell preform <xref ref-type="fig" rid="fig6">Figure 6</xref>(b) and can be pressed by molds [<xref ref-type="bibr" rid="scirp.127195-ref43">43</xref>] . The engineers and researchers of ITM (Dresden, Germany) developed the net shape nonwoven (NSN) technique, where they used solid free forming (SFF) to process textile fibers into 3D nonwoven scaffolds <xref ref-type="fig" rid="fig6">Figure 6</xref>(c) without any negative mold or forging dies [<xref ref-type="bibr" rid="scirp.127195-ref45">45</xref>] .</p><p>Miura and Hosokawa showed 3D-shaped nonwovens using an electrochemical process [<xref ref-type="bibr" rid="scirp.127195-ref46">46</xref>] . Yin et al. combined melt-blown and spun bond processes to produce 3D nonwoven shells [<xref ref-type="bibr" rid="scirp.127195-ref47">47</xref>] . Dong described techniques and opportunities for 3D nonwoven shell preforms for the automotive industry [<xref ref-type="bibr" rid="scirp.127195-ref48">48</xref>] . Additionally, several informative publications have been reported on various aspects of 3D nonwoven preforms [<xref ref-type="bibr" rid="scirp.127195-ref49">49</xref>] [<xref ref-type="bibr" rid="scirp.127195-ref50">50</xref>] . However, not all these inventions and methods are suitable for technical yarns, which means depending on the product and demand one chooses the manufacturing technique.</p></sec><sec id="s2_4"><title>2.4. 3D Shells by Winding and/or Layup</title><p>Few unconventional methods like winding and/or layup processes have no convincing accomplishments in 3D thin shell textile preforms. Rolincik introduced the autoweave process, which was interpreted as 3D weaving [<xref ref-type="bibr" rid="scirp.127195-ref51">51</xref>] . <xref ref-type="fig" rid="fig7">Figure 7</xref>(a) shows one schematic diagram of the autoweave process. However, no images of the final product of the autoweave process are available so far. Khokar invented a noobing process, where no interlacement of fibers was recorded [<xref ref-type="bibr" rid="scirp.127195-ref52">52</xref>] . Khokar classified noobing process as a nonwoven 3D fabric-forming process and the final product of it was termed as noobed fabric but wrongly assumed 3D woven fabric. Moreover, the author classified noobing as a layup process according to the details and graphics available for it <xref ref-type="fig" rid="fig7">Figure 7</xref>(b) [<xref ref-type="bibr" rid="scirp.127195-ref52">52</xref>] . Khokar and Peterson revealed a noobing device [<xref ref-type="bibr" rid="scirp.127195-ref53">53</xref>] , although it is arguably not suitable for 3D thin shells. Nevertheless, a layup process like noobing can produce 3D-shaped forms [<xref ref-type="bibr" rid="scirp.127195-ref54">54</xref>] . Apart from autoweave and noobing, it has been reported that 3D thin shells are made using filament winding.</p><p>Filament winding is an established simple process for producing parts like spherical, cylindrical, and other forms. Aerospace filament winding has become impressively effective for contour parts at a premium price. It can be useful for making 3D thin shell preforms as shown in <xref ref-type="fig" rid="fig7">Figure 7</xref>(c) [<xref ref-type="bibr" rid="scirp.127195-ref55">55</xref>] . However, the productivity of the process depends on machine parameters like axis speed, preform geometry, and fineness of the fiber. Hopmann et al. presented a new winding strategy, which offers good productivity with reasonable costs [<xref ref-type="bibr" rid="scirp.127195-ref56">56</xref>] . McIlhagger et al. described filament winding and its manufacturing processes [<xref ref-type="bibr" rid="scirp.127195-ref57">57</xref>] .</p></sec></sec><sec id="s3"><title>3. Industrial 3D thin Shell Applications and Demands</title><p>The importance and impact of 3D thin shell textile preform are one of the underperformed research topics in the textile and composite industries. The important functionalities of 3D thin shells are required for industrial purposes. Shell forming is a complex action and foremost the fiber orientation. <xref ref-type="table" rid="table2">Table 2</xref> presents the state of the art for different 3D thin shell manufacturing techniques.</p><table-wrap id="table2" ><label><xref ref-type="table" rid="table2">Table 2</xref></label><caption><title> State of the art of 3D thin shell manufacturing</title></caption><table><tbody><thead><tr><th align="center" valign="middle"  rowspan="2"  >Process</th><th align="center" valign="middle"  colspan="5"  >3D thin shell manufacturing</th></tr></thead><tr><td align="center" valign="middle" >Shape</td><td align="center" valign="middle" >Size (mm)</td><td align="center" valign="middle" >Fiber orientation (degree)</td><td align="center" valign="middle" >Automation (fully/semi/not)</td><td align="center" valign="middle" >Cycle time (min)</td></tr><tr><td align="center" valign="middle" >Weaving</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >1. Folded up:</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Shuttle weft insertion</td><td align="center" valign="middle" >doubly contour</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >0, 90</td><td align="center" valign="middle" >not automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Origami</td><td align="center" valign="middle" >rectangle box</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >0, 45, 90</td><td align="center" valign="middle" >semi-automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >2. Variation of thread spacing:</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Koppleman’s process</td><td align="center" valign="middle" >hemispheres</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >0, 90</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Shape weaving</td><td align="center" valign="middle" >biaxial curves</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >0, &#177;45, 90</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >4:08 (e.g. indoor panel)</td></tr><tr><td align="center" valign="middle" >Knitting</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Spickel &amp; suspended stitch:</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >SHIMA SEIKI WholeGarment<sup>&#174;</sup> (e.g. SWG-XR)</td><td align="center" valign="middle" >domes, spheres</td><td align="center" valign="middle" >1250 - 1500</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >STOLL (e.g. CMS 320 TC)</td><td align="center" valign="middle" >tube, ellipse</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Nonwoven</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Net-shape nonwopven (NSN)</td><td align="center" valign="middle" >scaffolds</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Airlaying</td><td align="center" valign="middle" >web, hat</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Thermal through-air bonding</td><td align="center" valign="middle" >complex surface contours</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Winding and/or layup</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Filament winding</td><td align="center" valign="middle" >car seat</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr></tbody></table></table-wrap><sec id="s3_1"><title>3.1. Comparison of Recent 3D Textile Technologies and Industrial Demands for 3D Thin Shell Preforms</title><p>The ability and advantages of 3D thin shell textile preforms contribute to reducing composite component manufacturing costs. It is possible to make suitable 3D thin shell preforms using appropriate technology with greater automation <xref ref-type="table" rid="table3">Table 3</xref> illustrates the gaps between 3D thin shell manufacturing techniques and industrial requirements. It is not easy to discuss all limitations in one combined work to overcome the commercial hurdles. Therefore, continuous research and development are necessary to seal their place in the fields of technical textiles.</p><table-wrap id="table3" ><label><xref ref-type="table" rid="table3">Table 3</xref></label><caption><title> Comparison of recent 3D textile technologies and industrial requirements for 3D thin shells</title></caption><table><tbody><thead><tr><th align="center" valign="middle" >Application areas</th><th align="center" valign="middle" >Fulfilled industrial requirements</th><th align="center" valign="middle" >Gaps between 3D textile technolgy &amp; industrial demands</th><th align="center" valign="middle" >Remarks</th></tr></thead><tr><td align="center" valign="middle" >Aerospace</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Radome</td><td align="center" valign="middle" >automated, available sizes</td><td align="center" valign="middle" >production capacity, design complexity</td><td align="center" valign="middle" >requires feasible method to meet design criteria</td></tr><tr><td align="center" valign="middle" >Motor Vehicles</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Bonnet</td><td align="center" valign="middle" >automated, organized shape geometry</td><td align="center" valign="middle" >range of production process</td><td align="center" valign="middle" >prodcution cycle timefor light weight components</td></tr><tr><td align="center" valign="middle" >Indoor panel</td><td align="center" valign="middle" >automated, fiber orientation</td><td align="center" valign="middle" >organized eco-process with less costing</td><td align="center" valign="middle" >cost-effectiveness with a certain quality</td></tr><tr><td align="center" valign="middle" >Machinery &amp; equipment</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Shield</td><td align="center" valign="middle" >automated</td><td align="center" valign="middle" >limited fiber orientation, not suitable for each 3D-process</td><td align="center" valign="middle" >variable and controlled shape geometries</td></tr><tr><td align="center" valign="middle" >Pressure vessel</td><td align="center" valign="middle" >automated</td><td align="center" valign="middle" >all shapes are not possible directly through a 3D-process</td><td align="center" valign="middle" >choice of a particular technique as demand</td></tr><tr><td align="center" valign="middle" >Safety helmets</td><td align="center" valign="middle" >automated, standardized shape</td><td align="center" valign="middle" >commercial accountability, increase in the process channel</td><td align="center" valign="middle" >eco-process chain</td></tr></tbody></table></table-wrap></sec><sec id="s3_2"><title>3.2. Research Gaps and Future Needs</title><p>One of the most critical issues in the composite industry is to reduce weight by replacing heavy metal components. It has been reported that 50% - 75% weight reduction for some components is possible in the long term through carbon fiber-reinforced composites [<xref ref-type="bibr" rid="scirp.127195-ref4">4</xref>] . However, the absence of commercially available computational modeling and lack of automation in the processes are still major challenges for manufacturing 3D thin shell preforms. Three-dimensional thin shell textile preforms can be as lightweight components and they will add benefits to the automotive industries by optimizing fuel consumption. To succeed significantly with this mission, it is important to understand their long-term application requisites, replaceable opportunities with other 3D textile preforms, cost-effectiveness, the demand of consumers, and productivity. <xref ref-type="table" rid="table4">Table 4</xref> presents a few important examples of possible 3D thin shell preforms with existing demands and requirements.</p><table-wrap id="table4" ><label><xref ref-type="table" rid="table4">Table 4</xref></label><caption><title> Outlook of a few industrial thin shell applications and existing industrial requirements</title></caption><table><tbody><thead><tr><th align="center" valign="middle"  rowspan="2"  >Applications</th><th align="center" valign="middle"  colspan="5"  >Industrial requirements</th></tr></thead><tr><td align="center" valign="middle" >Shape</td><td align="center" valign="middle" >Size (mm)</td><td align="center" valign="middle" >Ply orientation (degree)</td><td align="center" valign="middle" >Automation (fully/semi/not)</td><td align="center" valign="middle" >Cycle time (min)</td></tr><tr><td align="center" valign="middle" >Aerospace</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Radome</td><td align="center" valign="middle" >spherical</td><td align="center" valign="middle" >46,000</td><td align="center" valign="middle" >0, 45, 60, 75, 90</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Curved indoor</td><td align="center" valign="middle" >oval</td><td align="center" valign="middle" >508 - 914</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Motor vehicles</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Bonnet</td><td align="center" valign="middle" >heart</td><td align="center" valign="middle" >1100 - 1420</td><td align="center" valign="middle" >0, 15, 60, 75, 90</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Indoor panel</td><td align="center" valign="middle" >curves, diagonal</td><td align="center" valign="middle" >915 - 2030</td><td align="center" valign="middle" >0, &#177;45, 60, 90</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Monocoque (e.g. ZR 19 race car)</td><td align="center" valign="middle" >elliptical</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >0, &#177;45, 90</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Wheel rim (e.g. 700C)</td><td align="center" valign="middle" >parabolic</td><td align="center" valign="middle" >622</td><td align="center" valign="middle" >0, &#177;45, 90</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Machinery &amp; equipment</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Shield (e.g. Chuck)</td><td align="center" valign="middle" >ring</td><td align="center" valign="middle" >254 - 660</td><td align="center" valign="middle" >0, &#177;45, 90</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Pressure vessels</td><td align="center" valign="middle" >cylindrical</td><td align="center" valign="middle" >165 - 425</td><td align="center" valign="middle" >&#177;45, &#177;55, &#177;65, &#177;75, &#177;85</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Safety helmets</td><td align="center" valign="middle" >hemispherical</td><td align="center" valign="middle" >510 - 630</td><td align="center" valign="middle" >0, &#177;45, 90</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Others</td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td><td align="center" valign="middle" ></td></tr><tr><td align="center" valign="middle" >Gypsum</td><td align="center" valign="middle" >cube</td><td align="center" valign="middle" >1200 - 2440</td><td align="center" valign="middle" >__________</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr><tr><td align="center" valign="middle" >Prosthesis</td><td align="center" valign="middle" >limb</td><td align="center" valign="middle" >180 - 198</td><td align="center" valign="middle" >0, &#177;45, 90</td><td align="center" valign="middle" >fully automatic</td><td align="center" valign="middle" >__________</td></tr></tbody></table></table-wrap></sec></sec><sec id="s4"><title>4. Conclusions</title><p>An overview of key manufacturing technologies, application possibilities, and existing gaps for 3D thin shell textile preforms are presented. The conventional machines and methods are still enough for producing other 3D textile preforms, but many new approaches are needed for manufacturing complex 3D thin shells. The progress in 3D nonwoven is very limited regarding thin shell preforms. However, 3D woven and 3D knitted shells offer many more versatilities than 3D shells produced by nonwoven, winding, and/or layup processes. The available machines for 3D thin shell textile preforms are only prototypes and not used for commercial production, which influences heavily the productivity and industrial demand. Although 3D shells are regarded as one important group of 3D textiles, they still require more attention and extensive studies. There are a few gaps to be filled for achieving the fullest potential of 3D thin shell textile preforms:</p><p>&#183; Lack of automation.</p><p>&#183; Special setup (i.e. weaving, knitting, nonwoven, winding, and/or layup).</p><p>&#183; Shape discrepancies due to process variation.</p><p>&#183; Additional downtime and setup costs for the change in shell geometry.</p><p>&#183; Alteration of properties of the final 3D product.</p><p>&#183; Problem in forecasting for design complexity and shape deformation.</p><p>&#183; Damage to the high-performance fibers due to improper settings and handling.</p><p>Researchers and engineers have been working to adopt new methods to simplify the process and improve efficiency with a higher degree of automation. Therefore, a new layup process for 3D thin shell preform will be published in a separate research paper.</p><p>Alternatively, 3D printing has drawn the attention of textile engineers and manufacturers immensely for its potential [<xref ref-type="bibr" rid="scirp.127195-ref58">58</xref>] . The 3D printing technology assists to create mock-ups in a short period. It will be no wonder if in the future 3D printed shell preforms replace 3D woven, 3D knitted, 3D nonwoven, and other 3D shells.</p>Challenges and Outlooks of This Research<p>This paper has provided a basic definition and a few important manufacturing methods with application areas mainly in technical textiles. However, it is a challenge to convince experts from different methodologies as each process offers a particular specification with distinct parameters and a few limitations. For example, Khokar mentioned noobing as nonwoven in his research works although in this paper author classified noobing as a layup process. In relation to the definition of a 3D thin shell, a few points should be reviewed. Therefore, the manufacturing processes must be studied further for their complex design and requirements. The tooling needed for the manufacturing has to be budget-friendly with an easy assembly process, and the design should support real weight reduction.</p><p>The realization of this underperformed research topic will definitely allow textile engineers and researchers to evaluate 3D thin shell preform characteristics, as well as more practice in building prototypes using simplified design programs. A brief description of different 3D thin shell manufacturing processes in this study will assist textile engineers to fabricate and classify the newly designed preforms as 3D thin shells.</p></sec><sec id="s5"><title>Conflicts of Interest</title><p>The author declares no conflicts of interest regarding the publication of this paper.</p></sec><sec id="s6"><title>Cite this paper</title><p>Hoque, M.T. 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