A method is provided for the design and manufacture of tufted patterned textiles having selected yarn densities that may vary for different pattern palette colors and in different areas of a pattern.

A shiftable backing feed or shiftable needle assembly is utilized with a tufting machine having reciprocating needles and gauge parts for seizing or cutting yarns wherein yarn placement patterns can be utilized to tuft at different gauge densities while maintaining the same pattern sizes and appearance.

A shiftable backing feed or shiftable needle assembly is utilized with a tufting machine having reciprocating needles and gauge parts for seizing or cutting yarns wherein yarn placement patterns can be utilized to tuft at different gauge densities while maintaining the same pattern sizes and appearance.

A shiftable backing feed or shiftable needle assembly is utilized with a tufting machine having reciprocating needles and gauge parts for seizing or cutting yarns wherein yarn placement patterns can be utilized to tuft at different gauge densities while maintaining the same pattern sizes and appearance, and gauge parts are adapted for high density stitching.

A shiftable backing feed or shiftable needle assembly is utilized with a tufting machine having reciprocating needles and gauge parts for seizing or cutting yarns wherein yarn placement patterns can be utilized to tuft at different gauge densities while maintaining the same pattern sizes and appearance, and gauge parts are adapted for high density stitching.

A shiftable backing feed is utilized with a tufting machine having reciprocating needles and gauge parts for seizing yarns at a plurality of fixed heights, wherein fabric support apparatus reciprocates in synchronization with the cycles of the needle bar to support the backing during penetration of the backing fabric yet allow backing shifts between stitches.

A multi-needle tufting gun for use in robotic tufting includes a support and a plurality of tufting modules mounted to the support, wherein at least one tufting module is movably mounted to the support such that the at least one tufting module is selectively spaced relative to at least another tufting module mounted to the support. Each tufting module comprises a tufting needle. A spacing actuator mounted to the support selectively moves the at least one tufting module relative to another tufting module, wherein the selective relative movement is in at least one axis across a tufting plane of a sheet of backing material to be tufted. In some examples, the tufting module includes self-contained tufting cartridges. There is also disclosed a tufting frame for conveying a backing material through a tufting area.

A multi-needle tufting gun for use in robotic tufting includes a support and a plurality of tufting modules mounted to the support, wherein at least one tufting module is movably mounted to the support such that the at least one tufting module is selectively spaced relative to at least another tufting module mounted to the support. Each tufting module comprises a tufting needle. A spacing actuator mounted to the support selectively moves the at least one tufting module relative to another tufting module, wherein the selective relative movement is in at least one axis across a tufting plane of a sheet of backing material to be tufted. In some examples, the tufting module includes self-contained tufting cartridges. There is also disclosed a tufting frame for conveying a backing material through a tufting area.

A system and method for tufting sculptured and multiple pile height patterned articles, including controlling placement of yarns fed to the needles of the tufting machine by a yarn feed mechanism to form varying patterns includes a backing support over which the backing is fed, and which lifts/and biases the backing to a raised position. As the backing material is fed through the tufting machine, a series of loopers or hooks engage and pick loops of yarns from the needles. The yarn feed mechanism will be controlled to create a tension in selected loops of yarns, to cause the backing material to be pulled against the bias or spring force applied by the backing support toward the needle plate of the tufting machine to create tufts of different pile heights.

A system and method for tufting sculptured and multiple pile height patterned articles, including controlling placement of yarns fed to the needles of the tufting machine by a yarn feed mechanism to form varying patterns includes a backing support over which the backing is fed, and which lifts/and biases the backing to a raised position. As the backing material is fed through the tufting machine, a series of loopers or hooks engage and pick loops of yarns from the needles. The yarn feed mechanism will be controlled to create a tension in selected loops of yarns, to cause the backing material to be pulled against the bias or spring force applied by the backing support toward the needle plate of the tufting machine to create tufts of different pile heights.