Manufacturing

Stitched for Strength: The Physics of Stiff, Knitted Fabrics

admin — Wed, 30 Jul 2025 12:39:36 +0000

Stitched for Strength: The Physics of Stiff, Knitted Fabrics admin Wed, 07/30/2025 - 08:39

School of Physics Associate Professor Elisabetta Matsumoto is unearthing the secrets of the centuries-old practice of knitting through experiments, models, and simulations. Her goal? Leveraging knitting for breakthroughs in advanced manufacturing — including more sustainable textiles, wearable electronics, and soft robotics.

Matsumoto, who is also a principal investigator at the International Institute for Sustainability with Knotted Chiral Meta Matter (WPI-SKCM2) at Hiroshima University, is the corresponding author on a new study exploring the physics of ‘jamming’ — a phenomenon when soft or stretchy materials become rigid under low stress but soften under higher tension.

The study, "Pulling Apart the Mechanisms That Lead to Jammed Knitted Fabrics," was published this week in Physical Review E, and also includes Georgia Tech Matsumoto Group graduate students Sarah Gonzalez and Alexander Cachine in addition to former postdoctoral fellow Michael Dimitriyev, who is now an assistant professor at Texas A&M University.

The work builds on the group’s previous research demonstrating that knitted materials can be mathematically ‘programmed’ to behave in predictable ways. “These properties are intuitively understood by people who knit by hand,” Matsumoto says, “but in order to manipulate and use these behaviors in an industrial setting, we need to understand the physics behind them. This new research is another step in that direction.”

An Unexpected Twist

Gonzalez, who led the research, first became interested in jamming while conducting adjacent research. “I was using model simulations to characterize how different yarn properties affect the behavior of knitted fabrics and noticed a strange stiff region,” she recalls. “In our previous research, we had also seen this behavior in lab experiments, which suggested that what we were seeing in the simulations was a genuine phenomenon. I wanted to investigate it further.”

After digging into the topic, she realized that what she was seeing was called ‘jamming.’ In knits, Gonzalez explains, jamming occurs when stitches are packed tightly together, and the fabric resists stretching. Although it’s a well-known phenomenon, the physics has mostly been investigated in granular systems, like snow or sand, rather than fabrics.

“In fabrics, when you pull softly, the response is surprisingly stiff, but when you start pulling harder and harder, the stitches rearrange, and the material softens,” Matsumoto says. “In granular systems, this is a little like how avalanches work. At low forces, the snow pack is solid, but when the slope is steep, the force of gravity liquidizes that snow pack into an avalanche.”

“In fabrics, it is a little like having a tangle in a piece of jewelry,” she adds. “If you pull on it, it gets quite stiff, but if you loosen the knot, the chain can reconfigure, and it's not so stiff.”

Unraveling the Physics of Jamming

Using a combination of experiments with industrially knitted fabrics and computer models, the team analyzed what causes jamming in fabrics and how to control it. “We wanted to determine how different yarn properties impacted jamming,” Gonzalez explains. “Our goal was to understand the mechanics of jamming through how yarn interacts at various touchpoints in stitches.”

The team found that both machine tension and yarn thickness played a key role in making a fabric more or less jammed, and that jamming behaves differently depending on which direction the fabric is stretched.

“When you stretch a knit along the rows, the stiffness of the yarn causes fabric jamming. Jamming in the other direction is due to yarn contacts,” says Gonzalez. “We also showed that the impacts of changing machine tension and yarn thickness differ depending on fabric direction.”

“Discovering that fabric jamming works differently in different directions was a key insight,” she adds. “To our knowledge, the physics of this has never been explored before.”

Modern Innovation — With a Centuries-Old Technique

The research dovetails with Matsumoto’s WPI-SKCM2 Center work, which involves investigating fundamental aspects of knots and chirality. The Center is interested in a class of materials called “knotted chiral meta matter” that could lead to more sustainable materials.

For example, knitting — which leverages chiral knots — could be used to create more elastic fabrics from natural materials. “In many cases, manufacturers use yarns that combine, for example, polyester, cotton, and elastane to create a desired elasticity,” Matsumoto says. “Our research suggests that manipulating the topology of the stitches could lead to a similar elasticity, reducing the need for petroleum-based fibers and creating a more sustainable textile.”

“Knitting has the potential to be extremely useful in manufacturing, but knowledge has typically been shared through intuition and word of mouth,” she adds. “By creating these mathematical models, we hope to formalize that knowledge in a way that’s accessible for large-scale manufacturing — so we can leverage this centuries-old intuition for modern innovation.”

Funding: This work was supported by the World Premier International Research Center Initiative (WPI), Ministry of Education, Culture, Sports, Science and Technology of Japan; National Science Foundation (NSF); and Research Corporation for Science Advancement (RCSA).

DOI: https://doi.org/10.1103/g94g-c6tt

Summary sentence

Physicists unravel the secrets of the centuries-old practice of knitting in a new study that explores the physics of ‘jamming’ — a phenomenon when soft or stretchy materials become rigid under low stress but soften under higher tension.

Summary

Researchers in the School of Physics unravel the secrets of the centuries-old practice of knitting in a new study that explores the physics of ‘jamming’ — a phenomenon when soft or stretchy materials become rigid under low stress but soften under higher tension.

Dateline

Fri, 07/25/2025 - 12:00

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Scientists Pinpoint Hazards for Engineered Stone Fabrication Shop Workers

admin — Mon, 28 Jul 2025 18:23:41 +0000

Scientists Pinpoint Hazards for Engineered Stone Fabrication Shop Workers admin Mon, 07/28/2025 - 14:23

You've probably seen fabricated stone countertops on an HGTV remodeling show — and you might even have them in your own home.

The durable, affordable, and highly customizable product debuted in Italy in the 1970s and continues to grow in popularity. Between 2010 and 2018, U.S. imports of engineered stone slabs increased by 800%. One report predicted that global demand will increase 5.4% each year, to reach 97 million square meters by 2028.

Sometimes referred to as manufactured stone or quartz (which is, confusingly, also the name of one of its main components), to the untrained eye, the material looks no different from natural stone. One of its biggest advantages is that it can be made to resemble marble, granite, or nearly any other stone.

Beneath the material’s familiar smooth surface, however, lie safety risks for engineered stone workers.

Research conducted by a team of Georgia Tech scientists demonstrates that everyone in a fabrication shop is at risk, not just the workers cutting and fashioning the material.

The group included members of the Enterprise Innovation Institute’s Safety, Health, and Environmental Services (SHES) program: Jenny Houlroyd, Hilarie Warren, Brandon J. Philpot, and Sean Castillo. Together with Jhy-Charm Soo of Georgia Southern University, they recently published their findings in Oxford Academic.

The study divided engineered stone workers into four risk groups and charted their relative exposure to the material’s chief hazard: respirable crystalline silica.

A “Toxic Product”

Engineered stone differs notably from its natural counterpart, both in composition and in danger to worker health.

A stone slab cut from the ground, such as granite or marble, comprises several different minerals and typically has a concentration of 40% or less of mineral crystalline silica — usually quartz, which is the most abundant form of crystalline silica.

Engineered stone, however, can contain more than 90% silica. Slabs are produced when silica is crushed, combined with synthetic resins, and compressed using heat or pressure.

During fabrication, these slabs are cut and shaped by powered hand tools. The resulting dust contains tiny particles of respirable crystalline silica. Once inhaled, some of the particulate may stay in the lungs and cause an inflammatory response.

While crystalline silica is released from both natural and engineered slabs during fabrication, the engineered slabs’ significantly higher percentage of silica poses a much greater risk to human health.

A growing body of research indicates that breathing engineered stone dust leads to lung inflammation and can cause acute silicosis, an untreatable lung disease.

“I would classify engineered stone as a really toxic product,” said Houlroyd, manager of occupational health services at SHES. “When you have something that’s high-risk, you have to prepare for systems to fail and have backup measures.”

Committed to Safety

Over six years, the SHES research group collected air-sampling data, making 17 visits to 11 Georgia stone fabrication shops. The shops had all requested air-sampling services offered by SHES.

“The companies agree that by working with us, they commit to correcting the hazards and reducing exposures, as much as is feasible,” Houlroyd noted.

Because most kitchen and bathroom countertop fabrication shops are small employers, workers often complete a variety of tasks, resulting in a range of exposure factors.

The research team recommended that all manufactured stone fabrication workers wear respirators, such as an N95 mask. For employees who are the most exposed, they recommended a respirator with a powered air-purifying element or supplied air.

But personal protective equipment (PPE) alone does not ensure safe conditions.

“Most of the workers in this industry are relying on respirators as their primary source of protection, and they need a lot more to protect them,” explained Houlroyd. “PPE is the last line of defense, and safety needs to be addressed from all angles.”

Part of that multifaceted strategy includes repeated monitoring of air quality and equipment. It’s also crucial for employers to make sure that exposure risks are understood by all workers — not just employees, but also contract and day laborers, as well as those working for cash.

More Than Just a Job

As members of SHES, the Georgia Tech research team members are first and foremost health and safety consultants, with expertise spanning industrial hygiene, environmental compliance, and Occupational Safety and Health Administration (OSHA) regulations.

For Houlroyd, worker safety is not just a professional calling; it’s also a personal mission.

“My dad got sick with brain cancer from exposure to contaminants on the job, and he died four years ago,” she said.

“Though he didn’t work in the manufactured stone industry, his story is representative of many people who go to work each day to feed their family, are not aware of workplace hazards, and then find themselves sick.”

The public can play a part in worker safety, too.

“Consumers have a choice and can educate themselves about what type of countertop materials they choose to have installed — like how we look at food labels for nutritional information,” said Warren, who oversees the OSHA Training Institute Education Center at Georgia Tech.

“We should be aware of the risk to workers, as well as how the installation process in our homes should be properly managed to prevent dust contamination,” she added.

A Zero-Risk Solution

In 2024, Australia eliminated the risks associated with engineered stone fabrication. Despite having enacted stronger regulations in 2019, the country continued to see a rise in silicosis cases resulting from exposure to respirable crystalline silica.

Australia’s solution? Enacting a ban on the import and fabrication of the material until its safe manufacture can be demonstrated.

In their report, the Georgia Tech group recommends that the U.S. do the same. As Houlroyd put it, “I would love to see our country find a safer substitution and take this dangerous product off the market.”

____________________

Title: “Respirable dust and respirable crystalline silica exposures among workers at stone countertop fabrication shops in Georgia from 2017 through 2023”

Conflict of interest: Jenny Houlroyd has served as an expert witness in silicosis legal cases unrelated to this research. All other authors declare no conflict of interest.

Funding: The U.S. Department of Labor, Occupational Safety and Health Administration (OSHA) as part of the OSHA 21(d) Consultation Program grant.

DOI: https://academic.oup.com/annweh/advance-article/doi/10.1093/annweh/wxaf014/8116008?utm_source=advanceaccess&utm_campaign=annweh&utm_medium=email

Summary sentence

Engineered stone has been in use for homes since the 1970s but creates serious health hazards for workers who produce them.

Summary

Australia enacted a ban on the import and fabrication of manufactured stone slabs because of health hazard concerns. Researchers from Georgia Tech and Georgia Southern University recommend the U.S. do the same.

Dateline

Mon, 07/28/2025 - 12:00

eve.tolpa@innovate.gatech.edu

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Eve Tolpa
eve.tolpa@innovate.gatech.edu

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Georgia Manufacturing Extension Partnership at Georgia Tech Celebrates 65 Years of Service

admin — Thu, 24 Jul 2025 22:43:40 +0000

Georgia Manufacturing Extension Partnership at Georgia Tech Celebrates 65 Years of Service admin Thu, 07/24/2025 - 18:43

The Georgia Manufacturing Extension Partnership, a program of the Enterprise Innovation Institute at Georgia Tech, received recognition by Gov. Brian P. Kemp at the Georgia State Capitol for 65 years of service to the manufacturing industry.

The commendation acknowledged GaMEP for leveraging its world-renowned expertise and resources to advance manufacturing and economic prosperity across the state, supporting an industry that adds $82 billion to the economy and employs 425,000 residents, according to the National Association of Manufacturers.

This impact reflects decades of intentional growth and support for the industry. By 1960, more than 4,500 manufacturers had planted roots across Georgia — the result of strategic efforts by state leaders, with economic development assistance from Georgia Tech, to industrialize the economy. But growth brought new challenges. Manufacturers needed technical support to stay competitive. In response, the Georgia General Assembly voted to establish the Georgia Tech Industrial Extension Service (now known as the GaMEP). This created statewide field offices that provide a direct link between industry and innovation, delivering on-site technical expertise to help manufacturers thrive.

“Our role is to support those manufacturers so together we can help grow the state’s economy — and we’ve been really successful at that,” said Tim Israel, GaMEP director and EI2 associate vice president for corporate engagement/firm-based programs. “In 2024, Georgia experienced a significant return on its investment with the GaMEP generating an impressive $294 for every state dollar allocated to manufacturing projects. This remarkable outcome highlights the critical importance of the state’s strategic investments in strengthening Georgia’s manufacturing sector.”

Over the past decade alone, the GaMEP has provided assistance and education to more than 3,900 manufacturers across 144 counties, helping them create or retain 14,500 jobs, invest $1 billion in capital improvements, realize $3.5 billion in sales, and save nearly $450 million in costs. The GaMEP primarily serves small- to medium-sized manufacturers with 75% employing less than 250 workers. Its top-served industries include fabricated metal products, food, machinery, and chemical and transportation equipment manufacturing.

“When Georgia manufacturers become more productive and profitable, they hire more people, pay better wages, and stabilize local economies, especially in rural and underserved areas of the state,” said David Bridges, EI2 vice president. “This also creates pathways for career advancement for frontline workers who might not have had previous opportunities.”

Today, GaMEP’s reach spans 10 regions across the state, each led by a dedicated region manager who lives and works locally, offering manufacturers direct, knowledgeable connections to its expert team, valuable resources, and diverse partners.

“The GaMEP has been a trusted collaborator and valued partner in strengthening manufacturing across Georgia,” said Lloyd Avram, Georgia Association of Manufacturers CEO and president. “Together, we’ve supported thousands of manufacturers statewide — helping them embrace innovation, improve operations, and remain competitive. We appreciate their extensive expertise and shared dedication to advancing the industry, and we look forward to continuing our work together to ensure Georgia remains one of the best states for manufacturing.”

GaMEP’s impact and success by region, according to the Georgia Department of Economic Development regions:

Coastal Region

Counties: Bryan, Bulloch, Camden, Chatham, Effingham, Glynn, Liberty, Long, McIntosh, and Screven.
Manufacturers served: 269.
Jobs created/retained: 283.
Capital improvement investment: $23,171,292.
Costs saved: $1,645,061.
Sales realized: $13,965,000.
Success story: Roger Wood Foods.

East Region

Counties: Burke, Columbia, Glascock, Hancock, Jefferson, Jenkins, Lincoln, McDuffie, Richmond, Taliaferro, Warren, Washington, and Wilkes.
Manufacturers served: 169.
Jobs created/retained: 3,899.
Capital improvement investment: $127,754,280.
Costs saved: $14,771,582.
Sales realized: $975,465,000.
Success story: Nutritional Resources.

East Central Region

Counties: Barrow, Clarke, Elbert, Greene, Jackson, Jasper, Madison, Morgan, Newton, Oconee, Oglethorpe, and Walton.
Manufacturers served: 209.
Jobs created/retained: 621.
Capital improvement investment: $19,703,035.
Costs saved: $2,535,494.
Sales realized: $29,486,000.
Success stories: Creature Comforts Brewing Company and Poly Tech Industries.

Metro Atlanta Region

Counties: Cherokee, Clayton, Cobb, DeKalb, Douglas, Fayette, Fulton, Gwinnett, Henry, and Rockdale.
Manufacturers served: 1,601.
Jobs created/retained: 2,928.
Capital improvement investment: $235,763,480.
Costs saved: $112,083,262.
Sales realized: $844,679,890.
Success stories: Compass Technology Group, Construction Specialties, and Highland Forge.

Middle Region

Counties: Baldwin, Bibb, Crawford, Houston, Jones, Monroe, Peach, Pulaski, Putnam, Twiggs, and Wilkinson.
Manufacturers served: 170.
Jobs created/retained: 972.
Capital improvement investment: $121,814,846.
Costs saved: $8,810,950.
Sales realized: $300,213,400.
Success story: Unified Defense.

Northeast Region

Counties: Banks, Dawson, Forsyth, Franklin, Habersham, Hall, Hart, Lumpkin, Rabun, Stephens, Towns, Union, and White.
Manufacturers served: 280.
Jobs created/retained: 1,029.
Capital improvement investment: $88,443,395.
Costs saved: $63,999,228.
Sales realized: $259,453,900.
Success story: Freudenberg Sealing Technologies.

Northwest Region

Counties: Bartow, Catoosa, Chattooga, Dade, Fannin, Floyd, Gilmer, Gordon, Haralson, Murray, Paulding, Pickens, Polk, Walker, and Whitfield.
Manufacturers served: 387.
Jobs created/retained: 1,090.
Capital improvement investment: $ $92,948,931.
Costs saved: $141,460,651.
Sales realized: $326,366,408.
Success story: Trenton Pressing.

South Region

Counties: Appling, Bleckley, Candler, Dodge, Emanuel, Evans, Jeff Davis, Johnson, Laurens, Montgomery, Tattnall, Telfair, Toombs, Treutlen, Wayne, Wheeler, and Wilcox.
Manufacturers served: 176.
Jobs created/retained: 969.
Capital improvement investment: $219,300,221.
Costs saved: $6,596,254.
Sales realized: $39,632,275.
Success story: Healthy Pet.

Southeast Region

Counties: Atkinson, Bacon, Ben Hill, Berrien, Brantley, Brooks, Charlton, Clinch, Coffee, Cook, Echols, Irwin, Lanier, Lowndes, Pierce, Tift, Turner, and Ware.
Manufacturers served: 166.
Jobs created/retained: 281.
Capital improvement investment: $20,684,800.
Costs saved: $3,098,700.
Sales realized: $77,724,500.
Success stories: CJB Industries and South Georgia Pecan.

Southwest Region

Counties: Baker, Calhoun, Colquitt, Decatur, Dougherty, Early, Grady, Lee, Miller, Mitchell, Seminole, Terrell, Thomas, and Worth.
Manufacturers served: 130.
Jobs created/retained: 130.
Capital improvement investment: $12,266,730.
Costs saved: $1,682,790.
Sales realized: $5,002,020.
Success story: Sweet Grass Dairy.

West Region

Counties: Chattahoochee, Clay, Crisp, Dooly, Harris, Macon, Marion, Muscogee, Quitman, Randolph, Schley, Stewart, Sumter, Talbot, Taylor, and Webster.
Manufacturers served: 111.
Jobs created/retained: 713.
Capital improvement investment: $37,948,131.
Costs saved: $3,197,600.
Sales realized: $69,588,348.
Success story: Oneda Corporation.

West Central Region

Counties: Butts, Carroll, Coweta, Heard, Lamar, Meriwether, Pike, Spalding, Troup, and Upson.
Manufacturers served: 234.
Jobs created/retained: 1,658.
Capital improvement investment: $90,750,763.
Costs saved: $89,931,074.
Sales realized: $615,900,002.
Success stories: Complete Truck Bodies and Mountville Mills.

For more information about GaMEP’s impact, including impact by county, visit gamep.org/statewide-impact.

About the Georgia Manufacturing Extension Partnership
The Georgia Manufacturing Extension Partnership, a program of the Enterprise Innovation Institute at Georgia Tech, serves manufacturers by offering solution-based assistance that promotes top-line growth and reduces bottom-line cost. The GaMEP, a member of the U.S. Department of Commerce National Institute of Standards and Technology Manufacturing Extension Partnership, has advanced manufacturing and economic prosperity in Georgia since 1960. For more information, visit gamep.org and like/follow on Facebook, LinkedIn, X, and YouTube.

Summary sentence

Gov. Brian Kemp recognizes GaMEP history and impact serving manufacturers in Georgia.

Summary

The commendation celebrates GaMEP’s commitment to supporting manufacturers across the state through educational opportunities and technical assistance.

Dateline

Thu, 07/24/2025 - 12:00

peralte@gatech.edu

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Business and Economic Development

Manufacturing

Stitched for Strength: The Physics of Stiff, Knitted Fabrics

An Unexpected Twist

Unraveling the Physics of Jamming

Modern Innovation — With a Centuries-Old Technique

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Scientists Pinpoint Hazards for Engineered Stone Fabrication Shop Workers

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Georgia Manufacturing Extension Partnership at Georgia Tech Celebrates 65 Years of Service

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