Buckling of knitted fabric wrapped around a rigid cylinder

Abstract Knitted fabrics exhibit high flexibility due to their periodic loop structures formed by bent yarns. Under compressive loading, they develop three-dimensional (3D) wrinkling patterns that reflect nonlinear interactions between yarn elasticity and local loop deformations, as observed when the sleeves of a sweater are rolled up. Despite their widespread use in garments and medical textiles, the relationship between loop-level geometry and macroscopic buckling remains less understood. Here, we investigate the 3D deformation of knitted fabrics wrapped around a rigid cylinder under uniaxial compression. Circumferential and axial stitch numbers are systematically varied to determine how loop geometry affects the evolution of wrinkle patterns. Samples with a small number of circumferential stitches exhibit sequential wrinkle formation from the compressed end, leading to an accordion-like wrinkle pattern, whereas those with a larger number of stitches form helical wrinkles simultaneously across the surface. Wrinkle morphology changes progressively with stitch geometry, accompanied by systematic variations in compressive force, loop deformation, and helical wrinkle angle. The development of helical wrinkles originates from subtle structural asymmetries introduced during manufacturing processes, including the tension applied during knitting and the direction of sample assembly. These results demonstrate that small variations in local loop deformation can lead to substantial differences in wrinkle morphology, highlighting the sensitivity of macroscopic buckling to microscopic structural features. The study establishes a direct link between loop-level mechanics and global deformation behavior, providing a basis for the predictive design of knitted structures with tailored mechanical responses and complex 3D patterns.