A new machine is changing the product logic for warp knitting mills. KARL MAYER's RJ 4/2 EL, the latest addition to the RASCHELTRONIC® family, integrates jacquard, electronic shogging, and multi-bar systems into a single platform, directly targeting the core application of Body Mapping. This means fabric is no longer uniform; instead, it features differentiated elasticity, breathability, and support across zones, precisely matching the needs of different body parts.
Technically, the RJ 4/2 EL's breakthrough lies in its zone-knitting capability. Traditional warp knitting machines either do jacquard or multi-bar elastic structures, rarely achieving both fine patterns and zonal performance on one machine. The RJ 4/2 EL uses electronically controlled jacquard guide needles and independent shogging systems to set different stitch densities, structures, and patterns in designated areas during the same knitting process. For example, a bra cup area can be knitted with high-support mesh, while the side panels use elastic plain weave for comfort and fit.
This capability directly addresses the core demands of the lingerie and athleisure markets in recent years. Consumers no longer want a generic sports bra; they demand 'shock-proof for running, stretchable for yoga, and invisible for daily wear.' Brands have had to manage multiple fabrics and lamination processes, leading to high costs and long lead times. The RJ 4/2 EL allows mills to achieve seamless transitions between functional zones on a single piece of fabric, eliminating post-knitting joining steps while improving comfort and design freedom.
For warp knitting mills, this machine means upgrading from standard elastic fabrics to high-value functional fabrics. According to industry data, the unit cost of functional jacquard fabrics for premium sports bras and shapewear is two to three times that of ordinary warp-knitted elastic fabric, but gross margins are 15 to 20 percentage points higher. The ROI logic for the RJ 4/2 EL lies in its versatility: one machine can cover categories from lingerie to sportswear, reducing reliance on multiple dedicated machines and shortening prototype development cycles.
Market response shows that leading warp knitting mills in Europe and Southeast Asia have begun testing the machine, focusing on smart lingerie (with integrated conductive paths for sensors), shapewear (gradient pressure knitting), and compression garments (alternating breathable and compressive zones). These applications all rely on Body Mapping design, and the RJ 4/2 EL is one of the few devices capable of achieving this on a single machine.
Notably, this launch reflects a broader industry trend: electronification and intelligence are evolving from auxiliary functions to core knitting methods. The RASCHELTRONIC® series already includes several models, but the RJ 4/2 EL has a clearer positioning—it is not meant to replace existing equipment but to create a new product category: one-piece functional zoned fabrics. For brands, this means a simplified supply chain; for mills, it means higher technical barriers and stronger pricing power.
Below are three actionable recommendations based on this trend: