Methods are provided for producing patterned nonwoven materials and patterned laminated multilayer materials which include one or more layers of nonwoven. A nonwoven with heat-activatable binder fibers or binder materials is heated, subjected to patterned pressure. This softens or melts the binder and allows movement of the fibers in the nonwoven according to the pattern pressure. Then, the nonwoven is cooled so that the binder solidifies to lock a durable three-dimensional pattern into the structure. With a multilayer layup, for example, including a substrate layer, an adhesive layer, and a nonwoven layer, the layup is heated to melt the adhesive and soften binder in the nonwoven, then subjected to pattern pressure such as by being pressed with patterned plates, belts, or rollers, and cooled to bond the layers together, and to bond the fibers in the nonwoven according to the pattern pressure so as to fix the pattern. The processes may be carried out in batch mode or continuously using a flatbed laminating machine with heating and cooling zones. Engraved rollers, which may be heated or cooled depending on process conditions, can also be employed. The resulting materials exhibit stable three-dimensional patterns, typically 1-25 mm deep, suitable for functional and aesthetic applications.

Methods are provided for producing patterned nonwoven materials and patterned laminated multilayer materials which include one or more layers of nonwoven. A nonwoven with heat-activatable binder fibers or binder materials is heated, subjected to patterned pressure. This softens or melts the binder and allows movement of the fibers in the nonwoven according to the pattern pressure. Then, the nonwoven is cooled so that the binder solidifies to lock a durable three-dimensional pattern into the structure. With a multilayer layup, for example, including a substrate layer, an adhesive layer, and a nonwoven layer, the layup is heated to melt the adhesive and soften binder in the nonwoven, then subjected to pattern pressure such as by being pressed with patterned plates, belts, or rollers, and cooled to bond the layers together, and to bond the fibers in the nonwoven according to the pattern pressure so as to fix the pattern. The processes may be carried out in batch mode or continuously using a flatbed laminating machine with heating and cooling zones. Engraved rollers, which may be heated or cooled depending on process conditions, can also be employed. The resulting materials exhibit stable three-dimensional patterns, typically 1-25 mm deep, suitable for functional and aesthetic applications.