Automotives consist of a significant number of textile-based components. This study examined how process parameters affect the quality of needled sustainable recycled polyester fiber nonwoven components used in the automotive industry. Using a 2×2 factorial design, the impact of needle penetration depth and stroke frequency on nonwoven properties, namely, weight, thickness, tensile strength, dimensional stability, flammability, and wear resistance was investigated. Recycled polyester fibers (6.7 dtex and 11 dtex) were carded, cross-lapped and needle-punched, then subsequently a binder added for the required mouldability to produce samples. Results indicate that stroke frequency has a direct relationship with fabric weight, while needle penetration decreases thickness with increase due to greater fiber compaction and interlocking. Tensile strength increased with increase in stroke frequency, needle penetration, and weight. Higher needle penetration reduced elongation percentages in the machine direction. The burning rate was influenced by fabric weight and finishes applied, with PET fibers demonstrating self-extinguishing properties. Binder application reduced bearding and enhanced abrasion resistance through improved inter-fiber bonding. No dimensional changes were observed after heat exposure. These findings provide practical guidance for optimising needle-punched nonwoven manufacturing for automotive interior applications.

Keywords

Needle punching, recycled PET nonwovens, automotive textiles, process optimisation, quality characteristics