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This paper aims to study the yarn cross-section shape which is a very important yarn physical parameter and has a dominant effect on the physical structure of the yarn. Four factors affecting the yarn cross section, i.e. twist multiplier, Roving hank, spinning system and doubling technique, were investigated.

In past researches, the yarn cross-sectional area was calculated by considering any one yarn radius giving the approximate yarn cross-sectional area by assuming the yarn as a circular one.

In this study, a testing instrument is fabricated as shown in Plates 1 and 2 for yarn cross-section measurement and a novel method for calculating the correct yarn cross-sectional area of the yarn was developed.

In the past, no such studies have been conducted on the yarn cross-section studies because of the various limitations of the yarn cross-section measuring or testing instruments.