When elastic fabrics no longer mean uniform stretch across the entire piece, the entire design logic for lingerie and athleisure is rewritten. KARL MAYER officially launched the RJ 4/2 EL in July 2026, a new member of its RASCHELTRONIC® family. The machine uses an electronically controlled jacquard guide bar system to create varying structures and densities in a single knitting process, enabling a single fabric to offer different levels of support, breathability, and compression in different zones.
Technical Logic: Zoned Design at the Knitting Stage
Traditionally, achieving body mapping effects required brands to cut and sew panels of different fabrics or rely on post-finishing. This added cost and often created discomfort at seam lines. The RJ 4/2 EL moves the design process to the knitting stage. Its electronic jacquard system controls each guide bar independently, allowing the machine to automatically switch between structures and yarn tensions based on a pre-set pattern or ergonomic data. This means a single fabric can have higher density in the shoulder area, lower density in the waist, and seamless transitions between breathable back zones and supportive front zones.
From an industry perspective, this technology has the most direct impact on the elastic fabric supply chain. Previously, sports bra or shapewear brands had to order multiple types of elastic fabrics and assemble them during cutting and sewing. Now, one knitting order can produce a complete zoned elastic fabric, significantly shortening development cycles and reducing inventory pressure.
Market Impact: From Smart Lingerie to Athleisure
KARL MAYER positioned the RJ 4/2 EL for smart lingerie and sporty athleisure designs, which aligns with market trends. According to industry data, the global sports bra market exceeded $18 billion in 2025, with zoned compression and seamless design as the fastest-growing segments. Traditional warp knitting machines often had to compromise between elasticity and structural diversity. The RJ 4/2 EL allows mills to offer both high stretch and localized structural variation, a capability previously only partially achievable through more complex circular knitting or weaving processes.
For brands, this opens up product differentiation. A simple sports vest can now feature a honeycomb breathable zone on the back and mild compression support on the chest, all achieved through the fabric structure itself without any auxiliary materials or finishing. This enhances the wearing experience and reduces supply chain complexity, allowing brands to cover more functional needs with fewer SKUs.
Industrial Cluster Response: Who Benefits First
China is the world's largest warp knitting fabric production base, particularly in industrial clusters like Haining (Zhejiang), Changle (Fujian), and Wujiang (Jiangsu). The RJ 4/2 EL offers these mills a pathway from homogeneous competition (e.g., standard spandex elastic fabrics) to high-value functional textiles. A leading warp knitting company in Haining placed an initial order in Q1 2026, planning to use the machines for high-end sports bras and medical-grade compression stockings. Mills in Changle, known for lace and tricot, see the machine's design flexibility as a way to enter the fashion lingerie market.
However, the investment threshold is significant. KARL MAYER's RASCHELTRONIC® series is positioned at the high end, with unit prices often exceeding €500,000. For small and medium-sized mills, order stability and technical team capabilities must be carefully evaluated. Maintenance and programming of the electronic jacquard system require specialized training, which may slow adoption rates.