Multilayer weaving for seamless apparel production

A process for making a bifurcated tubal structure, the process comprising:

• weaving the bifurcated tubal structure in four layers,
• wherein the four layers are stacked on a weaving machine,
• wherein the bifurcated tubal structure comprises a first section connected to a second section,
• wherein the first section comprises each of the four layers connected in a larger tube,
• wherein the second section comprises sequential pairs of the four layers connected in two smaller tubes, and wherein the weaving is selected from the group consisting of shuttle weaving or shuttleless weft insertion system.

A process for making a bifurcated tubal structure, the process comprising:

• a) setting a warp sheet comprising warp yarns on a weaving machine;
• b) dividing the warp yarns between at least 8 harnesses, wherein four sets of warp yarns are distributed among the at least 8 harnesses, and wherein the four sets of warp yarns correspond to four layers of woven fabric, L1, L2, L3, and L4;
• c) implementing a first sequence of at least 8 sheds, wherein a first weft yarn is inserted into each of the four layers in a first order that connects the four layers of woven fabric in a larger tube, and
• optionally implementing a modified first sequence of the at least 8 sheds, wherein the first weft yarn is inserted into each of the four layers in a modified first order that connects the four layers of woven fabric in the larger tube and wherein at least two of the four layers are not continuously connected;
• d) repeating step c) until the larger tube is formed to a first desired length;
• e) implementing a second sequence of at least 8 sheds, wherein a second weft yarn is inserted into each of the layers L1 and L2 and a third weft yarn is inserted into each of the layers L3 and L4, in a second order that connects the layers L1 and L2 in a first smaller tube and the layers L3 and L4 in a second smaller tube, and
• optionally implementing a modified second sequence of the at least 8 sheds wherein the second weft yarn is inserted into each of the layers L1 and L2 and a third weft yarn is inserted into each of the layers L3 and L4, in a modified second order that connects the layers L1 and L2 in a first smaller tube, the layers L3 and L4 in a second smaller tube, and wherein the layers L1 and L2 and/or the layers L3 and L4 are not continuously connected;
• and
• f) repeating step e) until the first smaller tube and the second smaller tube are a second desired length,
• wherein the larger tube is folded while on the weaving machine,
• wherein the first smaller tube and the second smaller tube are staked while on the weaving machine,
• wherein a movement of the at least 8 harnesses in step c) is set by the first sequence of the at least 8 sheds and optionally the modified first sequence of the at least 8 sheds, and the movement of the at least 8 harnesses in step e) is set by the second sequence of at least 8 sheds and optionally by the modified second sequence of the at least 8 sheds, and
• wherein the larger tube is connected to the first smaller tube and the second smaller tube.