Advanced Textile interview questions

125 questions with answers (TEX-301 to TEX-425). Try each one aloud before reading the answer.

Textile Fibers

TEX-301 · A customer wants a cool, quick-drying summer shirt. Which fibre blend would you propose and why?

A polyester-cotton or polyester-lyocell blend with a moisture-wicking polyester (or a modified cross-section such as channelled polyester) and a breathable weave. Cotton or lyocell gives comfort and absorbency; polyester speeds drying and reduces wrinkling.

TEX-302 · How would you identify an unknown fibre in a fabric sample?

Start with a burn test and microscopy (longitudinal and cross-section views), then confirm with solubility tests in specific solvents and, for synthetics, melting point or FTIR spectroscopy. Blends need quantitative analysis by selective dissolution.

TEX-303 · How do you calculate the blend ratio of a polyester-cotton fabric by chemical analysis?

Dissolve the cotton in 70% sulphuric acid (or polyester in a suitable solvent), wash, dry and weigh the residue. Correct for moisture regain and any solubility correction factor, then express each component as a percentage of dry mass.

TEX-304 · Why would you choose lyocell over viscose for a premium fabric?

Lyocell has higher wet and dry strength, better dimensional stability and a closed-loop solvent process with lower environmental impact. Its main issue is fibrillation, which can be controlled or exploited for a peach-skin finish.

TEX-305 · How does cotton fibre maturity affect dyeing results?

Immature fibres have thin walls and absorb less dye, appearing as white or pale specks (neps) in dyed fabric. Mills control maturity through bale selection and remove neps in carding and combing.

TEX-306 · How would you engineer a polyester fibre to be more comfortable?

Use fine deniers or microfibres for softness, modified cross-sections (trilobal or channelled) for wicking, hydrophilic finishes or copolymers for moisture handling, and textured yarns for bulk and stretch.

TEX-307 · What fibre properties decide its use in high-performance protective clothing?

Tenacity and modulus for cut or ballistic resistance, LOI and thermal stability for flame resistance, chemical resistance, UV stability, comfort and cost. Aramids, UHMWPE, PBI and modacrylics are chosen by these trade-offs.

TEX-308 · How does the draw ratio affect the properties of a melt-spun filament?

Higher draw ratios increase molecular orientation and crystallinity, raising tenacity and modulus but reducing elongation and dye uptake. The draw ratio is set to give the required balance for the end use.

TEX-309 · How would you investigate low strength in a batch of polyester yarn?

Check intrinsic viscosity of the polymer, spinning and drawing conditions (temperatures, draw ratio, speed), moisture in chips, and any thermal degradation. Compare with standard batches and test for uniformity along the package.

TEX-310 · How does moisture regain affect commercial weight of fibres?

Fibres are traded at a standard (commercial) moisture regain, so invoiced weight is adjusted from the actual moisture. For example, cotton is traded at 8.5% regain; buying very moist fibre at actual weight would overpay for water.

TEX-311 · How would you select a fibre for a hospital bed linen contract?

Balance comfort, durability under industrial laundering at high temperatures, cost, shrinkage, and infection-control requirements. Polyester-cotton blends are common because they withstand frequent hot washing and dry faster than pure cotton.

Yarn Manufacturing & Spinning

TEX-312 · Ring-spun yarn shows high hairiness. How would you reduce it?

Check traveller weight and condition, spindle speed, ring and traveller wear, spinning triangle size, humidity and fibre properties. Compact spinning or adjusted twist reduces hairiness; singeing or air-vac at winding can also help.

TEX-313 · How do you decide between ring, rotor and air-jet spinning for a new product?

Ring gives the strongest, softest yarn for fine counts but is slow; rotor is fast and cheap for coarse counts with a harsher hand; air-jet is fast with low hairiness and good pilling resistance for medium counts. End use, count range and cost decide.

TEX-314 · How do you calculate the twist needed for a 30 Ne cotton yarn with twist multiplier 4.0?

TPI = TM × √Ne = 4.0 × √30 ≈ 21.9 TPI. Spindle speed and front roller delivery are then set to deliver that twist.

TEX-315 · Why does an increase in twist first increase and then decrease yarn strength?

Twist binds fibres together, increasing friction and strength, up to an optimum. Beyond it, fibres become more oblique to the yarn axis, so less of their strength contributes along the axis, and the yarn weakens.

TEX-316 · How would you reduce end breakage on a ring frame?

Check roving quality, traveller selection, ring condition, spindle centering, humidity, drafting settings and yarn twist. Analyse breaks by spindle to find mechanical faults, and track breaks per 1000 spindle hours.

TEX-317 · How does fibre length affect the choice of drafting system settings?

Roller settings must be slightly more than the effective fibre length; too close breaks fibres, too wide gives poor control of floating fibres and irregular yarn. Longer fibres allow wider settings and finer yarns.

TEX-318 · How do you plan a mixing of cotton bales for consistent yarn quality?

Use HVI data to select bales so averages and variation of key properties (micronaire, length, strength) stay constant across mixes, with bale laydown software and controlled mixing.

TEX-319 · How does spinning a finer count affect production and cost?

Finer counts need more twist and lower delivery speed per spindle, so production per spindle drops sharply, raising cost per kilogram. Better fibre (longer, finer) is also needed.

TEX-320 · How would you design a yarn for knitted T-shirts?

Use combed cotton or cotton blends with low twist for softness, low hairiness to reduce pilling, consistent evenness to avoid barre, and appropriate count for fabric GSM. Compact yarns improve appearance.

TEX-321 · How do you diagnose periodic faults in yarn using a spectrogram?

A spectrogram shows mass variation at specific wavelengths; a peak indicates a mechanical fault such as an eccentric roller or worn gear. The wavelength tells which machine part caused it.

TEX-322 · Why is yarn conditioning or steaming done after spinning?

Steaming or conditioning sets twist and reduces snarling, making yarn easier to handle in weaving and knitting. It also brings yarn to equilibrium moisture.

Weaving Preparation & Weaving

TEX-323 · Warp breakage is high on an air-jet loom. How do you investigate it?

Check size add-on and penetration, yarn quality, shed geometry, warp tension, humidity, heald and reed condition, and hairy yarn abrasion. Analyse breaks by cause and location to target the right fix.

TEX-324 · How would you choose the sizing recipe for a polyester-cotton warp?

Use a blend of starch and PVA or acrylic sizes for adhesion to both fibres, with a softener, at a target add-on of around 10–14%. Check size viscosity, add-on, and weaving performance, and ensure the size can be removed later.

TEX-325 · How does weave structure affect fabric strength and drape?

More interlacings (plain weave) give firmer, stronger fabrics with less drape; fewer interlacings (twill and satin) give softer, more drapeable fabrics with longer floats that snag more easily.

TEX-326 · How do you calculate the warp yarn requirement for an order?

Warp length × total ends × (1 + crimp %) × yarn linear density, plus waste allowances for loom and sizing. Convert to kilograms using tex or count.

TEX-327 · How would you design a fabric for a given GSM?

Choose yarn counts, ends per cm and picks per cm, and crimp so that GSM = (ends/cm × warp tex × (1 + crimp) + picks/cm × weft tex × (1 + crimp)) /10. Adjust to meet cover factor and strength requirements.

TEX-328 · Why might a loom produce weft bars and how are they prevented?

Changes in weft yarn lot, tension, beat-up or loom stoppages produce bars. Use consistent yarn lots, set correct loom settings, use start-mark prevention systems and ensure uniform take-up.

TEX-329 · How do you choose between dobby and jacquard for a design?

Dobby suits small repeating geometric designs using up to about 28 heald shafts; jacquard controls individual warp ends for large, complex designs. Jacquard costs more but gives greater design freedom.

TEX-330 · How do you calculate the efficiency of a weaving shed?

Efficiency = actual picks woven/theoretical picks at machine speed over the time period. Track stops by cause (warp, weft, mechanical) to identify improvements.

TEX-331 · How does reed count affect fabric?

The reed controls warp spacing; reed count sets ends per inch along with ends per dent. A wrong reed gives incorrect width and density.

TEX-332 · How do you reduce energy use on air-jet looms?

Optimise nozzle pressures and timing, use relay valve control, fix air leaks, use efficient compressors and match machine speed to fabric needs.

TEX-333 · How would you design a fabric for high tear strength?

Use stronger yarns, looser structures that allow yarn grouping at the tear (such as ripstop, basket or twill), and avoid over-finishing with resins.

Knitting

TEX-334 · A single jersey fabric shows spirality after washing. How would you fix it?

Use lower twist or balanced twist yarns, alternate S and Z yarn feeds, use more feeders or a tighter stitch, and apply suitable compaction and heat-setting for blends.

TEX-335 · How do you calculate the GSM of a single jersey fabric from loop length and count?

GSM = (courses/cm × wales/cm × loop length in cm × tex) / 10, using relaxed fabric dimensions. Changing loop length is the main lever for GSM.

TEX-336 · How would you reduce barre in knitted fabric?

Use yarns from consistent lots, control yarn tension, check feeders and cams, maintain uniform needle condition and mix yarn packages to avoid systematic variation.

TEX-337 · How do you design a knit fabric for compression sportswear?

Use elastane-containing yarns in a structure with controlled stretch and recovery, engineer pressure by varying stitch structure along the garment, and test pressure with gauges.

TEX-338 · How do you troubleshoot holes in circular-knitted fabric?

Check needles for damaged latches, yarn knots and weak places, yarn tension, take-down tension and cam settings.

TEX-339 · Why do knitted fabrics shrink more than woven fabrics, and how is it controlled?

Loops relax and distort during washing, changing dimensions. Control through compacting, relaxation drying, heat-setting synthetics and stitch length control.

TEX-340 · How do you choose machine gauge for a fabric weight?

Finer gauges with finer yarns give lighter, smoother fabrics; coarser gauges suit heavier yarns. Gauge is matched to yarn count using relationships between gauge and tex.

TEX-341 · How does warp knitting suit technical applications?

Warp knitting allows high speeds, stable structures, mesh and spacer fabrics, and inserting straight yarns for strength, ideal for nets, automotive and medical uses.

TEX-342 · How do spacer fabrics work?

Two surface layers connected by monofilament spacer yarns create a 3D structure for cushioning and breathability, used in mattresses, car seats and medical products.

TEX-343 · A knitted fabric comes out 15 GSM lighter than specified. What would you adjust?

Check yarn count first, then reduce stitch (loop) length slightly to increase courses and wales per cm, check take-down tension and feeder tension, and review relaxation and compacting in finishing, which also change GSM. Re-measure after full relaxation, not straight off the machine.

TEX-344 · How would you develop a seamless knitted garment?

Use whole-garment knitting machines programmed with garment shape, reducing cutting and sewing waste and creating comfortable seamless products.

Nonwovens

TEX-345 · How would you design a nonwoven for a face mask filter?

Use meltblown polypropylene with fine fibres and electret charging for filtration efficiency, laminated between spunbond layers for strength, balancing filtration efficiency with breathability (pressure drop).

TEX-346 · How do you choose between needle punching and hydroentanglement for a product?

Needle punching suits thicker, coarser products like geotextiles and felts; hydroentanglement gives softer, cleaner, cloth-like fabrics for wipes and medical uses, with higher energy cost.

TEX-347 · How do you calculate filter quality factor?

Quality factor = −ln(penetration)/pressure drop. A higher value means better filtration for a given airflow resistance.

TEX-348 · How would you improve the strength of a thermally bonded nonwoven?

Optimise bonding temperature, pressure and bond area, use bicomponent fibres, and improve fibre orientation and web uniformity.

TEX-349 · How do you design a nonwoven geotextile for drainage?

Choose fibre type, weight and thickness to provide in-plane flow, adequate permeability and filtration opening sizes matching soil.

TEX-350 · Why are wipes made from blends of viscose and polyester?

Viscose gives absorbency and softness; polyester gives strength and cost benefits. Blends balance performance and price.

TEX-351 · How do you measure filtration efficiency?

Challenge the media with particles of known size and measure upstream and downstream concentrations at a set airflow.

TEX-352 · How would you reduce linting in nonwoven wipes?

Improve fibre entanglement or bonding, use longer fibres, optimise hydroentanglement energy and apply binders.

TEX-353 · How do you choose fibres for flushable wipes?

Use dispersible fibres such as short cellulose with low entanglement so they break apart in water, tested under flushability standards.

TEX-354 · How does web uniformity affect nonwoven performance?

Variation causes weak spots and inconsistent filtration or absorbency. Online monitoring ensures uniform basis weight.

TEX-355 · How do you choose between spunbond and meltblown processes?

Spunbond produces stronger, coarser fibres; meltblown produces fine fibres for filtration. Many products combine both (SMS).

Wet Processing & Pretreatment

TEX-356 · Dyed cotton fabric shows uneven shade patches. How do you trace whether pretreatment caused it?

Check absorbency and residual size across the fabric with drop tests and iodine tests, measure pH, residual peroxide and whiteness, and compare with uneven areas. Uneven scouring or bleaching often shows as patchy dyeing.

TEX-357 · How do you optimise peroxide bleaching to avoid fibre damage?

Control peroxide concentration, pH (around 10.5–11), temperature and time; use stabilisers to control decomposition and remove metal ions. Monitor whiteness and degree of polymerisation.

TEX-358 · How would you reduce water use in pretreatment?

Combine desizing, scouring and bleaching, use counter-current washing, enzymes and low liquor ratio equipment.

TEX-359 · How do you check that desizing has removed the starch size?

Use the iodine test: a blue-black colour shows residual starch, while yellow-brown shows it is removed. Also measure weight loss after desizing and absorbency (drop test); residual size causes uneven scouring and dyeing.

TEX-360 · How do you prepare polyester-cotton fabric for dyeing?

Singeing, desizing, scouring and bleaching under conditions suitable for both fibres, followed by heat-setting the polyester to stabilise dimensions.

TEX-361 · Why does residual alkali on prepared fabric cause dyeing problems?

Alkali left from scouring changes the dyebath pH, which can make reactive dyes fix too early or unevenly and affect shade. Fabric should be neutralised and its pH checked (typically 6–7) before dyeing.

TEX-362 · How is whiteness measured after bleaching?

A spectrophotometer measures reflectance and calculates a CIE whiteness index under a standard illuminant with UV content, so the effect of optical brighteners is included. Visual assessment alone is unreliable because brighteners and light sources change perception.

TEX-363 · How do you prevent pinholes (catalytic damage) during peroxide bleaching?

Iron or copper particles catalyse rapid peroxide decomposition and burn holes in the fabric. Remove metal contamination from fabric and machines, use sequestering agents and stabilisers, and avoid rusty equipment and hard water.

TEX-364 · How do you set heat-setting conditions for polyester knit fabrics?

Set temperature (around 180–200 °C), time and width for dimensional stability, considering elastane content which needs lower temperatures.

TEX-365 · How do you plan wet processing for wool?

Use gentle scouring, avoid alkali damage, control felting, and use specific processes like carbonising and shrink-resist treatments.

Dyeing

TEX-366 · A reactive-dyed fabric has poor wash fastness. What do you check?

First check wash-off: hydrolysed and unfixed dye left after poor soaping is the most common cause. Then check fixation conditions (alkali amount, temperature, time), water hardness and dye selection, and confirm by testing a sample re-soaped in the lab.

TEX-367 · How would you cut salt usage in reactive dyeing?

Use low-salt reactive dyes with high substantivity, lower the liquor ratio, consider cationised cotton that attracts anionic dyes without salt, and optimise the recipe to avoid excess. Salt reduction lowers effluent TDS, which is hard to treat.

TEX-368 · How do you scale a lab dyeing recipe to bulk production?

Apply correction factors for liquor ratio, machine type, heating rate and dye lot strength derived from historical lab-to-bulk data, run a sample or first batch, measure ΔE and adjust. Consistent pretreatment of lab and bulk fabric is essential.

TEX-369 · Shade varies between batches of the same recipe. How do you investigate?

Compare dye lot strength by standard lab dyeings, check water quality, fabric preparation (absorbency, residual peroxide, pH), process records (temperatures, times, additions) and machine loading. A systematic cause usually shows up in one of these.

TEX-370 · How do you dye a polyester-elastane fabric without damaging the elastane?

Dye at lower temperatures (about 120–125 °C instead of 130 °C) and for shorter times, choose disperse dyes that build at lower temperature with good wash fastness, and heat-set at a temperature that stabilises the fabric without degrading elastane.

TEX-371 · How would you raise a dyehouse's right-first-time rate?

Standardise pretreatment, use automated weighing and dispensing, control water quality, calibrate lab-to-bulk factors, use process control on machines, and record and analyse every re-dye by cause. Each percentage point of right-first-time saves water, energy and time.

TEX-372 · A 400 kg batch must be dyed at a 2.5% shade. How much dye is needed, and what else do you calculate?

Dye = 400 × 2.5/100 = 10 kg. With a 1:8 liquor ratio, bath volume = 3200 L, so salt and alkali, given in g/L, are calculated on that volume (for example 60 g/L salt = 192 kg).

TEX-373 · How would you choose a dye class for cotton workwear that is washed industrially?

Industrial laundering needs very high wash and chlorine fastness, so vat dyes (or high-fastness reactive dyes for some shades) are preferred despite higher cost and complexity. Direct dyes would fade too quickly.

TEX-374 · How would you shorten the dyeing cycle on jet machines?

Use faster but controlled heating and cooling rates where levelness allows, dyes with compatible profiles, all-in-one processes, efficient overflow or hot rinsing and wash-off at high temperatures. Monitoring exhaustion online helps cut unnecessary hold times.

TEX-375 · How would you evaluate a new dye supplier before switching production?

Compare standard dyeings for strength and shade, fastness properties, compatibility in combination shades, reproducibility across lots, safety data and restricted-substance compliance, and total cost including recipe changes. Run a controlled bulk trial before switching.

Printing & Finishing

TEX-376 · How do you decide between rotary-screen and digital printing for an order?

Compare run length, number of colours, design changes, delivery time and cost. Rotary is cheaper for long runs once screens are made; digital wins for short runs, many designs and fast sampling, with no screens to engrave.

TEX-377 · Reactive prints look weak and dull. What would you check?

Check pre-treatment (absorbency, alkali or urea in the paste or pad), thickener choice, drying conditions, steaming time, temperature and moisture, and wash-off. Insufficient moisture during steaming is a frequent cause of low colour yield.

TEX-378 · How would you develop an easy-care finish for cotton shirts?

Use a low-formaldehyde or formaldehyde-free crosslinker with a catalyst, plus softener and polyethylene to protect tear strength. Optimise add-on and curing to reach target durable press ratings while keeping strength loss acceptable.

TEX-379 · How do you evaluate a durable water-repellent finish?

Use the spray rating test, contact angle measurements, and hydrostatic head where relevant, both before and after a specified number of wash cycles. Durability is as important as initial performance.

TEX-380 · What do you consider when applying an antimicrobial finish?

Choose an approved agent with a suitable mode of action, control add-on and durability to washing, test efficacy with standard methods, and assess skin safety and environmental impact. Claims must match regulatory rules.

TEX-381 · Pigment prints fail rub fastness. How do you correct them?

Increase binder content or use a better binder, check that curing reaches the required temperature and time, reduce pigment load if it exceeds what the binder can hold, and add a fixer or crosslinker. Softener choice can also affect rubbing.

TEX-382 · How do you calculate finish add-on in padding?

Add-on (% on fabric weight) = wet pick-up % × concentration in the pad liquor %. For 70% pick-up and 50 g/L product (about 5%), add-on ≈ 3.5% as product.

TEX-383 · How would you develop a flame-retardant curtain fabric for public buildings?

Select an inherently FR fibre (such as FR polyester) or a durable FR finish suitable for the fibre, apply at the correct add-on, and test to the required standard after the specified number of washes or dry cleanings.

TEX-384 · How do you control shrinkage in denim production?

Use compressive shrinkage (sanforising) and skew control in finishing, and set the process to the target residual shrinkage specified by the brand. Garment wash recipes must then be matched to the fabric.

TEX-385 · How do you design a finishing route for a cotton knit fabric?

Use relaxation drying, softening, and compacting to control shrinkage, width and GSM, and check spirality. Tubular or open-width processing is chosen according to fabric type and end use.

Textile Testing & Quality Control

TEX-386 · A buyer rejects a shipment for shade variation. How would you investigate?

Measure colour differences instrumentally against the approved standard, check shade-band or lot segregation, review dye lot and processing records, and check if the rejection is under a different light source (metamerism). Agree a corrective plan with the buyer.

TEX-387 · How would you set up a quality control plan for a weaving mill?

Define incoming yarn tests (count, strength, evenness), in-process checks (warping, sizing add-on, loom settings), fabric inspection (4-point system), and reporting by defect source. Use the data to target the biggest defect causes.

TEX-388 · How is statistical process control applied in spinning?

Plot control charts for count, CV%, strength and imperfections per sample; react to points outside limits or trends before they cause defective lots. SPC shifts quality control from inspection to prevention.

TEX-389 · How do you interpret Martindale abrasion results for upholstery?

Higher rub counts mean better durability; for example, domestic upholstery often needs 15,000–25,000 rubs and contract upholstery 30,000 or more. Results depend on the end point used and the fabric structure.

TEX-390 · How is UV protection factor (UPF) measured?

A spectrophotometer measures UV transmission through the fabric across the UV spectrum; UPF is calculated by weighting transmission with the solar spectrum and skin erythema response. Fabric construction, colour and fibre type affect UPF.

TEX-391 · Why is the strength of a fabric strip less than the sum of its yarn strengths?

Yarns in fabric are crimped and do not all reach their breaking load at the same time, and weak spots fail first. Fabric strength efficiency is usually below 100% of the sum of yarn strengths.

TEX-392 · How is fabric hand measured objectively?

The Kawabata (KES-F) or FAST systems measure tensile, shear, bending, compression and surface properties, and translate them into hand values such as stiffness, smoothness and fullness.

TEX-393 · How is colour fastness to perspiration tested?

Specimens with adjacent fabrics are soaked in acid and alkaline artificial perspiration solutions, pressed under load and incubated at body temperature, then graded for colour change and staining.

TEX-394 · How are acceptance limits set in the 4-point inspection system?

Defects get 1 to 4 points by length; points per 100 square yards are calculated for each roll. Buyers commonly accept rolls below about 40 points per 100 square yards, though limits vary by product.

TEX-395 · How do you validate a new testing instrument before using it?

Calibrate it, compare results with a reference instrument or interlaboratory standards, check repeatability and reproducibility, and document the method. Only then are results used for acceptance decisions.

Garment Manufacturing

TEX-396 · How would you reduce fabric wastage in a garment factory?

Improve marker efficiency with CAD nesting, control spreading and end losses, use accurate fabric width data, plan cut orders to minimise leftover, and reuse or recycle cutting waste.

TEX-397 · How many operators are needed to produce 1200 shirts in an 8-hour shift with an SMV of 18 min at 70% efficiency?

Operators = (target × SMV)/(available minutes × efficiency) = (1200 × 18)/(480 × 0.70) = 21,600/336 ≈ 64.3, so about 65 operators. Line balancing then assigns operations so each operator's load is similar.

TEX-398 · How would you set up a lean garment production line?

Move toward small-batch or single-piece flow in cells, balance work, reduce work in progress, visualise performance, and run continuous improvement with operators. Lead time and defects fall sharply.

TEX-399 · How do you control quality on a sewing line?

Use inline inspection with traffic-light systems for operators, end-of-line checks, defect tracking by operation and operator, and feedback to fix causes rather than just reworking.

TEX-400 · How do you plan production for many styles with different SMVs?

Calculate capacity in standard minutes, schedule styles by delivery date and line capability, account for learning curves when styles change, and keep buffer capacity for urgent orders.

TEX-401 · How do you select sewing thread for a jeans garment?

Choose a strong core-spun polyester thread with suitable ticket size for heavy seams, colour matched to design, and test seam strength and abrasion resistance after washing.

TEX-402 · How would you reduce rework in garment manufacturing?

Analyse defects by type and operation, fix root causes (training, machine settings, patterns), use first-piece approval and inline checks, and track rework rates.

TEX-403 · How is the cost of a garment estimated?

Sum fabric cost (consumption × price), trims, labour (SMV × cost per minute), overheads, washing or printing, packaging, freight and profit margin.

TEX-404 · Where does automation help most in garment manufacturing?

Automated cutting, pocket setting, buttonholing and hemming, and material handling systems give the biggest gains; sewing complex 3D shapes is still hard to automate fully.

TEX-405 · How do you improve garment fit consistency across production?

Use accurate graded patterns, control fabric shrinkage before cutting, use cutting accuracy checks, and measure garments against spec sheets during production.

Technical Textiles

TEX-406 · How would you design a fabric system for firefighter turnout gear?

Use three layers: an outer shell of FR fibres (aramid, PBI) for flame and abrasion, a moisture barrier that blocks water and chemicals while breathing, and a thermal liner for insulation. Balance heat protection with heat stress.

TEX-407 · How is a woven vascular graft designed?

Use biocompatible polyester yarns woven or knitted to a controlled porosity that limits blood leakage while allowing tissue ingrowth, often with a coating such as collagen or gelatin. Strength, kink resistance and compliance are tested.

TEX-408 · How do you choose between carbon, glass and aramid fibres for a composite?

Carbon gives the highest stiffness and low weight at high cost; glass is cheaper with good strength; aramid offers impact and ballistic resistance but poor compressive strength. The choice depends on loads, weight and budget.

TEX-409 · How do you design a geotextile filter for a soil?

Choose an apparent opening size small enough to retain soil particles, high enough permeability so water flows freely, and resistance to clogging, based on soil gradation criteria.

TEX-410 · How are ballistic fabrics tested?

Panels are shot with standard projectiles at specified velocities, measuring penetration and back-face deformation according to standards such as NIJ.

TEX-411 · How would you design a wearable ECG shirt?

Integrate textile electrodes made from conductive yarns at chest positions, ensure good skin contact through compression, route conductive tracks to a detachable electronics module, and test washability and signal quality.

TEX-412 · How are airbag fabrics designed and tested?

High-tenacity nylon 6,6 yarns are woven densely, sometimes coated, and tested for tensile and tear strength, air permeability under dynamic pressure, seam strength and ageing.

TEX-413 · How do you select filter media for a hot flue gas?

Consider operating temperature, chemical exposure (acids, alkalis), particle size and abrasion. Fibres like PPS, aramid, PTFE or glass suit high temperatures; finishes improve dust release.

TEX-414 · How would you develop a cut-resistant glove?

Use high-performance fibres such as UHMWPE, often with glass or steel cores, knit into a seamless shell and coated for grip; test cut resistance to standards such as EN 388.

TEX-415 · How do breathable waterproof fabrics work?

Microporous membranes (like ePTFE) have pores too small for liquid water but large enough for vapour; hydrophilic membranes transport vapour by diffusion. Seams must be taped.

Sustainability & Textile Machinery

TEX-416 · How would you reduce the carbon footprint of a textile mill?

Improve energy efficiency (heat recovery, efficient motors, compressed air management), switch to renewable energy, optimise processes to reduce reprocessing, and measure emissions to target the largest sources.

TEX-417 · How do you design an effluent treatment plant for a dyehouse?

Equalise flow and pH, use physicochemical treatment for colour, biological treatment for COD, and tertiary treatment such as membranes for reuse. Design for variable load and sludge handling.

TEX-418 · How do you evaluate recycled fibre quality for spinning?

Test fibre length distribution, short fibre content, strength, contamination and colour, and run spinning trials to confirm yarn quality.

TEX-419 · How do you implement predictive maintenance on textile machines?

Install sensors for vibration, temperature and power, analyse data to detect anomalies, and schedule maintenance before failures.

TEX-420 · How can chemical use in wet processing be reduced?

Optimise recipes using right-first-time data, use automated dosing to avoid over-addition, combine processes such as scouring and bleaching, use enzymes in place of harsh chemicals, and reuse standing baths where quality allows.

TEX-421 · How do you design garments for easier recycling?

Use single-fibre (mono-material) fabrics and threads, avoid elastane blends where possible, limit hard-to-separate trims and coatings, choose detachable buttons and zips, and label fibre content clearly so sorters can route the garment correctly.

TEX-422 · How is the water footprint of a fabric calculated?

Sum green, blue and grey water used across fibre production, wet processing and finishing using lifecycle data.

TEX-423 · How do you assess machine efficiency in a spinning mill?

Compare actual production with theoretical capacity at set speeds, break down losses into doffing, end breaks, maintenance and idle time, and track overall equipment effectiveness (OEE = availability × performance × quality) to target the biggest losses.

TEX-424 · How would you apply Industry 4.0 in a textile mill?

Connect machines with IoT sensors, collect real-time data on production and quality, use analytics and automation to optimise processes.

TEX-425 · How do you implement chemical management across a textile supply chain?

Publish a restricted substance list (RSL) for products and a manufacturing restricted substance list (MRSL), require chemical inventories and supplier declarations, audit suppliers, and test wastewater and products against limits such as ZDHC guidelines.

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