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The yarn is produced by extruding the material through a precision engineered hole called a spinneret, which determines the diameter and cross-sectional shape of the yarn. Before passing through the spinneret, the raw material has to be prepared to be extruded.
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Melt spinning is used to produce these yarns from thermoplastic and thermoset resins; the raw polymer chips are fed through a tube with a rotating inner screw that puts pressure on the polymer chips, ultimately melting them, which allows the polymer to flow through the spinneret.
This melting and extrusion process is continuous, meaning that yarn can theoretically be extruded indefinitely, which is why monofilament yarn is always continuous. Melt extrusion works for common materials like nylon, polyester, and polypropylene, among others.
The pressure generated to melt and extrude the material can be enormous, between 60- and 200-times atmospheric pressure, which is equivalent to the pressure between 600m and 2 kilometres below the surface of the ocean.
While this process is broadly similar to that used for multifilament yarns, more care has to be taken to prevent the newly extruded yarn from warping. For this reason, the extruded yarn has to travel through a water bath, from where it is drawn several times. The drawing process stretches and elongates the yarn, with nylon for example being drawn out to four times its original length. Once this drawing process is complete, the yarn is wound onto its packages. More information on the production process is available.
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