Polyester Mesh: A Complete Fabric Guide | Properties, ...

One of the pillars of Jason Mills’ knit fabrics product line is polyester mesh. This versatile material is used in various industrial and commercial applications, ranging from the aerospace and automotive sectors to the marine and medical sectors, as well as the indoor and outdoor recreational trade.

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This article provides an overview of polyester mesh, discussing its properties, advantages, and applications. It also outlines the differences between polyester and nylon mesh and the importance of fabric finishing and treatment in achieving particular end-use outcomes or performance.

An Overview of Polyester Mesh Fabric

The term “knit mesh fabric” describes material constructed with an open hole structure through knitting, as opposed to weaving. Beyond this broad characteristic, the design of a specific knit mesh material can vary in yarn, material weight, aperture opening, width, color, and finish. Polyester yarn is one of the most commonly used fibers in manufacturing knit mesh fabric.

Polyester consists of flexible, synthetic polymer fibers created through a chemical reaction between alcohol, carboxylic acid, and a petroleum byproduct. The resulting fibers are then stretched and oriented to form a strong yarn that naturally repels water, resists staining, degrades under ultraviolet light, and holds up to frequent use. It’s important to note that the inherent properties of polyester yarn, such as water resistance, often need enhancement during the finishing process if necessary for the material's performance.

Properties and Advantages of Polyester Mesh Fabric

Compared to other mesh materials, polyester fabric exhibits several advantageous properties, making it suitable for various industrial, commercial, and recreational applications:

• Ease of use and accessibility: Polyester is a common fiber available at most textile manufacturing facilities. When treated with a light resin, the mesh material is easy to install (sew) and clean, reducing time and labor required for integration and maintenance.
• Dimensional stability: Polyester fibers demonstrate good elasticity, allowing the material to return to its original shape after being stretched by up to 5–6%. However, mechanical stretch differs from fiber stretch; hi-stretch material can be designed using dimensionally stable yarns.
• Durability: Polyester mesh fabric is highly resilient, offering inherent resistance to damage and degradation from acidic and alkaline chemicals, corrosion, flames, heat, light, mold, mildew, and wear. Factors such as yarn weight (denier), entanglement, and filament count are critical in determining durability.
• Hydrophobicity: Polyester mesh repels water, resulting in superior pigment absorption (easier dyeing operations) and faster drying times (better moisture-wicking properties).

These characteristics make the material suitable for a wide range of applications, including environments exposed to outdoor and demanding conditions.

Fabric Applications

Polyester mesh fabric is highly versatile. Some industries that regularly employ this material include:

The exact properties exhibited by the polyester mesh fabric depend on the needs of the application and industry.

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Knit mesh fabric is commonly made from either polyester or nylon yarns. While the two synthetic polymers share some properties, such as lightweight, durability, and tear resistance, there are key distinctions that make them suitable for different applications.

• Nylon has a smoother and softer feel than polyester, making it more ideal for applications requiring high aesthetic quality or user comfort. However, factors such as a high filament count can make polyester just as drapey as soft nylon.
• Nylon is hydrophilic (absorbs water), while polyester is hydrophobic (repels water). Therefore, nylon is more likely to be bogged down with water in high-moisture environments, while polyester dries quickly in marine and aquatic settings.
• Nylon fibers are resistant to wear from bending and stretching, while polyester fibers inherently resist heat and UV rays. These qualities make nylon mesh more suitable for applications where the material will be regularly bent and stretched, and polyester mesh more suitable for use in stable environments exposed to heat and sunlight.

The Importance of Fabric Finishing and Treatment

The properties of polyester mesh fabric depend on several factors, especially the final stages of textile production, known as “the finish.” The finish is typically a topically applied chemical set by heat during a process called framing. These processes can affect the texture, weight, firmness, colorfastness, and resistances (UV, fire, etc.) of the final material.

As indicated, the properties of a fully finished and treated polyester mesh fabric vary depending on application and industry needs. Some examples include:

• Antibacterial finishes: Topically applied anti-microbial finishes eliminate bacterial growth on the fabric's surface. This is essential for equipment used in the medical and healthcare industries and sporting equipment as it minimizes odor-causing bacteria.
• Anti-static finishes: In operations involving sensitive electrical and electronic components, minimizing static charge buildup is crucial. Anti-static coatings reduce the risk of static discharge impacting components' integrity.
• UV resistant finishes: Untreated material exposed to UV rays fades and degrades over time. Polyester mesh used in outdoor environments (e.g., recreational equipment) requires UV inhibitors in the fabric finish or dye formulation to retain its integrity.
• Fire resistant finishes: Commonly used finishes for achieving fire resistance compliance in the automotive, aeronautical, and architectural interior industries (e.g., curtains and indoor recreational areas).

Jason Mills: The Experts in Polyester Mesh Fabric Solutions

Polyester knit mesh is a versatile material used across various industrial, commercial, and recreational sectors. Its strength, stability, and durability make it well-suited for many applications. Customers looking for high-quality polyester mesh fabric can rely on Jason Mills.

At Jason Mills, we specialize in manufacturing, warehousing, and distributing industrial polyester and nylon knit mesh. We offer a broad selection of standard textiles and custom-tailored fabric solutions for customers with specific needs. For additional information about our standard and custom textiles, contact us or request a quote today.

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This study shows that 3 (9.4%) of 32 patients had a late recurrence of their hernia following laparoscopic repair of a ventral hernia using a polyester mesh. Recurrences were only observed after 5 years of follow-up. This pattern of recurrence has not been reported before and highlights the importance of long-term follow-up in this patient group. Around 50% of recurrences for both open and laparoscopic ventral hernia are thought to happen within 2 years of operation; however, none were recorded in this study at that time point [4].

A possible explanation for hernia recurrence, particularly after bridging a defect, could be the loss of elasticity of the mesh with herniation into the defect. MRI studies have shown that an intra-abdominal pressure of 18.6 Kpa generates a force on the abdominal wall of 28 n/cm in the transverse direction and 22 n/cm in the longitudinal direction [5]. This pressure can be generated by coughing or jumping in a healthy adult and far exceeds the force required to convert the mesh used in this study from elastic to plastic [6].

Although CT scans confirmed stretching of the polyester mesh used to bridge the defect, this was not present in all patients and was minor in some cases, making it clinically irrelevant. Degradation of the mesh over time, combined with stretching, seems a more logical explanation for the late recurrence observed in our study. A study by Riepe et al. examining the in vivo hydrolysis of polyester vascular grafts demonstrated that hydrolytic degradation of polyester reduced their bursting pressure by 31.4% at 10 years [7]. Degradation is observed for all mesh products and is likely to weaken the mesh over time, considerably reducing the rupture force compared to its original state [8,9,10].

Differential outcomes for different meshes have been observed following both open and laparoscopic ventral hernia repair [2, 4, 11]. Generally, lightweight meshes break and lead to early recurrence. There is some evidence that suturing a defect rather than bridging it reduces early recurrence [1]. However, closing the defect was not performed in this study, yet all recurrences were seen after 5 years.

One of the drawbacks of this study is the lack of long-term clinical follow-up. In the current climate of COVID-19, this follow-up is not possible. An alternative is to look at recurrence through well-kept national registries. This identifies patients undergoing reoperation for their hernia, revealing that only 1 (3%) of the recurrences in our study would have been found. As many patients require a CT scan for various reasons as they age, while not perfect, this method will identify patients who are asymptomatic or do not wish for another operation for their hernia. Scotland has a national linked picture archiving and communication system (PACS), which acts as a comprehensive imaging registry for the population.

A further drawback of this study is the small number of patients, representing only one-third of those referred for operation over the 2-year period. However, all operations were performed by an experienced laparoscopic surgeon with a significant interest in hernia management. The unit acted as a tertiary referral center for complex hernias, with 18 patients having contaminated or dirty wounds from infected mesh or fistulae, while the remainder had complex, often recurrent hernias suitable only for retro-muscular or component separation repair.

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