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Ultrasuede®
was born with a revolutionary discovery ... and a remarkable manufacturing
innovation.
In 1970, after years of experimentation, Toray Industries scientist
Dr. Miyoshi Okamoto succeeded in creating the world’s first
ultra-microfiber. A few months later, his colleague Dr. Toyohiko
Hikota perfected a new process capable of transforming Dr. Okamoto’s
invention into an amazing new fabric, a non-woven material that
combined luxury with unprecedented performance.
This fabric, which was later trademarked as Ultrasuede®, combines
the rich aesthetics of a suede surface with benefits no animal product
could ever offer. Ultrasuede® is soft, supple and sensuous to
the touch. Yet it’s also resistant to stains and discoloration.
It’s even machine-washable or dry-cleanable.
How Is All This Possible?
The magic of Ultrasuede® begins with ultra-microfibers so fine
they cannot be seen by the human eye, ultra-microfibers so microscopically
minute a single pound of them could be stretched from the earth
to the moon—and back.
Transforming ultra-microfibers this fine into a practical fabric
demands a complex, multi-patented process, part of which is summarized
in the illustrations shown here.
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Ultrasuede®
begins with polymer ultra-microfibers spun so light and fine,
a strand measuring more than 50 miles long would weigh less
than a gram. |
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These ultra-microfibers
are extruded through protective spinnerets, creating what we
call the "Islands in the Sea" configuration, with
ultra-microfiber filaments "afloat" in each strand. |
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These strands are
then transformed via a complex process that includes ironing,
curling, cutting and needle-punching into a soft felt-like material
which is then impregnated with a special adhesive binder. |
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Once the material
is formed, the protective polymer coating is dissolved with
a solvent and the material is further processed to create a
fabric that is, almost paradoxically, as soft and supple as
it is strong and durable. Magnified thousands of times, this
cross-section reveals the densely complex yet mono-layer structure
of Ultrasuede®. |
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The end result: Ultrasuede®,
a richly complex non-woven fabric offering an unparalleled combination
of luxury, appeal, performance and ease of care for an extraordinary
array of applications. |
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The Fabric of the Future
The Ultrasuede® story began with a series of revolutionary discoveries.
It continues today with equally innovative R&D activities conducted
at Toray’s global Application Development Center in Italy.
One of the most advanced facilities of its kind anywhere in the world,
the Application Development Center combines European fashion and fabric
savoir-faire with Toray’s unsurpassed technological expertise.
The Application Development Center functions as a clearing house for
requests for technical assistance and application solutions from designers
and manufacturers on every continent. Its mission: To make sure Ultrasuede®
remains the fabric of the future.
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Ultrasuede®
is produced at technologically advanced plants such as this
one in Nera Montoro, Umbria, Italy. |
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Ultrasuede® manufacturing
facilities are ISO 9001-certified for quality and ISO 14001-certified
for safety and environmental protection. |
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Toray’s Applications
Development Center, also located in Nera Montoro, Umbria, Italy,
performs extensive R&D for customers around the world. |
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