Success Stories

The Challenge – Our client required an open hole mesh’ football jersey fabric that would not slit or tear upon impact. In addition, the fabric had to be visually appealing and look strong.

The Action – A special yarn was required to achieve the strength and requested stitch. Darlington collaborated with a premier yarn supplier to source and develop the material.

The Solution – Together with our client, we developed a revolutionary fabric that offers outstanding performance on-field and is visually appealing.

The Challenge – We were asked to develop a rigid fabric that supported the recycling objectives of our client’s licensee. In addition, the new fabric had to provide consistent physical and color quality across dye lots with quick turnaround from order receipt to ship date.

The Action – A close collaboration was required between Darlington, our client, the yarn manufacturer and sewing contractors.

The Solution – The fabric, developed from 100% post-consumer polyester (water bottles), was developed and launched and now has a three-year track record of success.

The Challenge – Our client needed a fabric that was durable, lightweight and breathable to be used as a close fitting vest component for a game-changing pad system

The Action – Darlington created a new fabric style by using specific denier yarns in an existing stitch pattern.
    
The Solution – We successfully integrated new yarns and spandex into the final product, which is changing contact sports forever.

The Challenge – A client asked us to develop a laminate product to be used in a lymphedema post-surgical wrap. Exact compression characteristics with no bowing affect when stretched were required. This was critical to avoid post-surgical infections due to the lack of proper blood flow around the incision.

The Action – Darlington developed various UBL (UnBroken Loop) products using higher denier spandex and a tricot with matching specifications.

The Solution – A higher denier spandex UBL and a tricot was proven so successful that another laminate using a different denier spandex in a UBL construction, along with sueded tricot, was added to the product line.

The Challenge – Our client applied their patented gel to a stretch UBL fabric worn as a prosthetic sock. The bond between the UBL and gel was not adequate, causing instability between the sock and the prosthesis.

The Action – Working with the client we experimented with stretch UBLs that had a higher loft on the back side of the fabric.

The Solution – We developed a stretch UBL that is napped on both sides. By raising fibers on the back side, the bonding of the gel application improved by 40%, resulting in superior stabilization in the end product.