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Help CenterThe Intelligent Electronic Cloth Tester Automatically Measures Warp and Weft Density, Yarn Width and Gap Area, and Complies With ISO 4602:2010
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In the high-end PCB (Printed Circuit Board) and CCL (Copper Clad Laminate) industry chain, the warp and weft density of electronic cloth and its across-width uniformity are core foundational indicators that determine the substrate thickness tolerance, dielectric performance stability and mechanical reliability of circuit boards. As downstream high-end electronic products continuously raise requirements for substrate precision, out-of-tolerance density deviation and local density unevenness on the fabric can directly lead to product downgrading, batch rejection, and even customer complaints and claims.
In the weaving process, factors including loom tension fluctuation, warp feed deviation, unstable weft insertion, and wear of heald frames and reeds will continuously affect the consistency of fabric density. The traditional sampling method relying on manual hand-held density gauges not only has slow reading speed and high labor cost, but also is affected by inspectors’ eyesight, experience and fatigue, making human error difficult to control.
Targeting the unique pain points of density testing in the electronic cloth industry, we launch the AI fully automatic electronic cloth warp & weft density testing equipment. Built on high-resolution optical imaging and centered on self-developed intelligent yarn recognition algorithms, it completes the full testing workflow of warp density, weft density, yarn width and gap area with one-stop report generation. It creates an efficient, accurate and traceable digital quality control solution for electronic cloth manufacturers, helping enterprises stabilize product grade rate, optimize weaving processes and reduce quality losses.
The equipment adopts a tabletop offline testing design and can be used directly in the quality inspection lab without retrofitting existing looms or production lines. It quickly identifies process abnormalities through high-frequency sampling inspections, upgrading quality management from post-production judgment to in-process intervention.
Four Core Values Reshaping Electronic Cloth Density Quality Inspection
Dramatically improved testing efficiencyAI automatically identifies and counts warp and weft yarns. It finishes the detection of warp & weft density, yarn width and gap area for a 5cm × 5cm electronic cloth sample in 30 seconds, with efficiency over 10 times that of manual microscopy inspection.
High testing accuracyEquipped with a micron-level high-definition optical imaging system and an AI recognition algorithm optimized for thin electronic cloth, it can accurately identify individual yarns in ultra-thin fabric types such as 1037 and 106. It features a scanning resolution of ≤2.5μm/pixel, a measurement accuracy of 5μm, and a yarn width measurement error of ≤10μm. The equipment automatically calculates multi-point density average, deviation and coefficient of variation (CV), precisely captures minor density fluctuations undetectable by manual inspection, and pinpoints hidden risks of early process drift.
Lightweight deployment and fast implementationNo retrofit is required for looms or production lines, and normal production rhythm remains undisturbed. The investment cost is far lower than full-width online inspection systems. A single unit covers the full range of electronic cloth products such as 7628, 2116 and 1080, supports quick switching of fabric type parameters, adapts to multi-variety and small-batch production scenarios, and improves return on investment.
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Full closed-loop digital quality controlAll testing data and original images are automatically archived. Historical data can be traced by batch, loom and fabric type, and density trend curves for individual rolls or single looms can be generated. It helps enterprises scientifically formulate cycles for reed replacement, loom maintenance and process calibration, continuously optimize weaving processes, stabilize product grade rate, and meet downstream customers’ compliance requirements for traceable quality inspection data.
Simplified Operation Workflow: Batch Quality Inspection Completed in 5 Minutes
No complex sample preparation is required for the entire testing process, with an extremely low operation threshold. Quality inspectors only need to cut a fabric sample of standard size, place it flat on the testing table, and start the test with one click. The equipment automatically completes the full workflow of focusing, scanning, recognition and calculation, and generates a standardized testing report within 30 seconds. The entire process from sampling to quality judgment takes no more than 5 minutes.
If the test finds density out of tolerance or substandard uniformity, the result can be quickly fed back to the weaving workshop for targeted adjustment of loom tension and warp feed parameters. This intercepts quality issues at the early production stage, minimizing raw material waste and downgrading losses.
Product Performance
Warp & Weft Yarn Width and Density Measurement Results
Electronic Cloth Gap Area Imaging Results
Product Components
Report Samples
Core Technical Specifications
| Test Types (optional) | Warp & weft density |
| Warp & weft density and width | |
| Warp & weft density and gap area | |
| Warp & weft density, width and gap area | |
| Objective Lens | 3X |
| Light Source | Natural light |
| Measurement Accuracy | 5μm |
| Scanning Resolution | ≤2.5μm/pixel |
| Measurement Error | ≤10μm |
| Yarn Width Range | 190–710μm |
| Yarn Density | 14–53 yarns/cm |
| Testing Duration | 30s |
| Sample Size | 6–8cm square or round electronic cloth samples |
| Counted Yarn Quantity | 70–265 yarns (fixed 5cm scanning length in warp and weft directions) |
| Scanning Area | 5cm × 5cm |
| Dimensions (L × W × H) | 31cm × 31cm × 54cm |
| Net Weight | 10kg |
| Power Supply | AC220V ±15%, 50/60Hz |
| Power Consumption | ≤100VA |
| Supported Operating System | Windows 10 |
Meet the standards
《ISO 4602:2010 Reinforcements — Woven fabrics — Determination of number of yarns per unit length of warp and weft》
《ISO 7211-2:1984 Textiles — Woven fabrics — Construction — Methods of analysis — Part 2: Determination of number of threads per unit length》
Full-Cycle Exclusive Services, Ensuring Long-Term Stable Equipment Operation
We provide not only testing equipment, but also industry-exclusive services covering the entire product lifecycle to ensure rapid implementation and sustained value of the equipment:
On-site delivery and commissioningProfessional engineers complete on-site installation and commissioning, and adapt algorithm parameters based on the customer’s main fabric types and internal control standards, ensuring the equipment is ready for mass production inspection upon delivery.
Systematic hands-on trainingOne-on-one training is provided for quality inspection and process teams, covering equipment operation, report interpretation, density abnormality traceability analysis, and routine maintenance, to ensure the team can master the operation quickly.
Customized function adaptationWe provide customized function development and scenario adaptation according to enterprises’ special testing requirements and sample specifications, to match personalized quality control systems.
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