Synthetic textile fibres part 5 of 6

Synthetic textile fibres

Welcome to the fifth instalment of our series dedicated to textile fibres, in this case synthetic fibres!

This guide will take you on a fascinating journey into the world of materials science, highlighting how synthetic fibres have become undisputed leaders in textile innovation and sustainability. If you are curious to find out how these materials are intertwined with our daily lives and the environmental challenges of the future, don't miss this in-depth study.

What are the most recent developments related to synthetic fibres?

Synthetic fibres are undoubtedly among the most versatile and widespread fibres in the world, and in recent years have undergone considerable innovations that have broadened their applications, both in technological and ecological terms. Below, we have attempted to make an in-depth analysis covering historical, political, chemical and application aspects.

Synthetic fibres have seen recent innovations aimed at sustainability and performance, such as:

• Antibacterial treatments: Ideal for sportswear, they counteract unpleasant odours thanks to nanotechnology or silver ions, an example of which is the first article we created and sold in our shop see link , in addition to this there are others for the beauty salon sector, facial body treatments, and make-up removers, see link.

• Water-repellent fabrics: Used in outdoor activity clothing, these fabrics offer a combination of water resistance and breathability (e.g. microporous membranes). We also developed a polyurethane article that made it possible to create the splash-resistant Q-Evolution Mask. You can find more information in the link

  • Perfect for fabrics designed to withstand harsh weather conditions, ensuring greater durability and functionality. When we develop our products and test innovative materials such as the TPU Evolution yarn used in the Q-Evolution Mask, we do so to push the boundaries of textile chemistry. We want to move beyond traditional water-repellent treatments (DWR) which, for decades, have relied on fluorocarbons (PFAS) and are now being replaced by alternative finishes that are often fragile. In the case of TPU, water repellency is an intrinsic and structural property of extruded thermoplastic polyurethane: it acts as a physical barrier, eliminating the need for fluorinated chemicals and guaranteeing the absence of PFAS, as analytically certified by the Oeko-Tex Standard 100 Class 1 certification. To give a concrete example of our approach, in the past we also extensively tested new water-repellent nanotechnologies, but we chose not to rely on them: our tests showed that after several washes they lost their properties, forcing us to constantly reapply them. Even though we are a small company, we always work with discernment and a critical eye. We believe that true sustainability stems from informed choices, analysed internally and never dictated solely by passing trends.

• Innovative Uses:

  • Technical fabrics for sailing and water sports, salt and UV resistant.

  • Biodegradable food packaging, derived from modified polyester (e.g. PHBV) that decomposes in 6 months. It is produced by micro-organisms and is known for its ecological properties, although PHBV has potential in the textile sector, its diffusion is still limited compared to more traditional materials, we will see developments in the near future, it is not certain that the fate of this material will be used in clothing.

Which other synthetic fibres exist?

Here is an overview of the main synthetic fibres:

• Acrilic: Lightweight and wool-like, used in jumpers and carpets.

  • Acrylic resins (polyacrylates) are polymers derived from acrylic monomers, with properties such as flame resistance, elasticity and antistaticity, used in paints, coatings, adhesives and dental materials.
    In Italy, the production of acrylic fibres began with Acsa in Marghera (Edison), which later passed to Montefibre. It mainly produced acrylic staple dyed pulp, ideal for woolen knitting yarns.
    Textile labelling: PC (Polyacrylic)

• Aramidics (Kevlar, Nomex): extreme heat and impact resistance (bulletproof vests, firemen's clothing)

  • Aramid fibre (or aramid, Kevlar) is a material made from aromatic polyamides, developed in 1965 in the USA. It is characterised by high tensile strength, light weight and resistance to cuts and impacts, and is used in construction and textiles. Compared to steel, it weighs five times less for the same strength and retains its properties even at high temperatures.
    Textile labelling : KE (Kevlar)
    Textile labelling : NM (Nomex)

• Clorovinile: Chemical resistant, used in industrial textiles.

  • Chlorovinyl (polyvinyl chloride, PVC) was used in the past in the textile industry, mainly to produce fibres such as Rhovyl, used in technical clothing and fireproof fabrics. However, due to its potential carcinogenicity, its use was gradually abandoned and today it is no longer used in textile production.

• Neoprene: Thermal insulation, used in diving suits.

• Poliammide (Nylon): Elasticity and strength (socks, ropes).

• Gore-Tex: Water-repellent and breathable membrane for outdoor jackets.

• Poliuretano (Elastane): Superior elasticity (sportswear), but much more, it can also be used heat-sealed giving different shapes and effects.

As a small curiosity, many synthetic fibres, including polyester, neoprene, polyurethane and Gore-Tex, have been used to make Marvel and DC superhero costumes, due to their great versatility.

Insights into Synthetic Fibres

Storia e Scoperta

• Polyester: Synthesised in 1941 by John Whinfield and James Dickson, marketed in the 1950s as a cheap alternative to cotton.

• Nylon: Invented in 1935 by Wallace Carothers (DuPont), it revolutionised the textile industry during WWII (short for World War II) (parachutes, socks).

• Kevlar: discovered by chance in 1965 by Stephanie Kwolek, it became a symbol of ballistic protection, such as bulletproof vests and other safety equipment.

• Gore-Tex: Born in 1969 from Bob Gore's insight into the expanded structure of PTFE (Teflon), this creates a microporous membrane that is impermeable to water but breathable, allowing water vapour to escape, has the ability to protect against water and wind while maintaining comfort and breathability, and has become a brand synonymous with high performance in adverse weather conditions.

Political aspects: The development of many fibres was accelerated by wars (e.g. Nylon for the military), creating geopolitical dependencies on oil. Today, environmental pressures push towards bio-polymers (e.g. PLA from maize starch, while being heat-sensitive and water-resistant). In textiles, PLA is gaining popularity for its ecological characteristics and functional properties, we will see if there are future developments.

Chemical and Physical Properties

• Polyester: is a hydrophobic material, resistant to creases and UV rays, and can be recycled, as in the case of PET bottles turned into yarn.

• Aramidic: Aramid fibres, like Kevlar, have a rigid molecular structure that gives them excellent mechanical and thermal resistance, allowing them to withstand temperatures up to 500°C; they are widely used in personal protection applications, such as bulletproof vests, and in industrial sectors for their light weight and tensile strength.

• Neoprene: is a thermal and chemical insulating material that is resistant to extreme temperatures, water and chemicals, making it ideal for applications in extreme environments such as diving suits, gloves and linings for industrial equipment.

• Polypropylene: is an inert, anti-bacterial material often used in thermal garments, masks and other sanitary products due to its resistance to moisture, light weight and ability to retain insulating properties.

• Polyamide: Commonly known as nylon, they are wear and abrasion resistant materials with good elastic and breathable properties; often treated with silver ions for their antimicrobial and odour control properties, they are used in sportswear, socks and technical fabrics due to their light weight, durability and ability to dry quickly.

Electrical properties: Most of the textile materials mentioned (polyester, polyamide, aramid, neoprene, polypropylene) are generally electrical insulators. There are exceptions, such as conductive fabrics, which can be created by combining insulating materials with conductive elements, such as carbon or metals. These conductive fabrics are used in wearable technology applications and wearable electronic devices.

Historical and Modern Uses

In the 1940s-50s: nylon replaced silk in stockings, becoming a symbol of female freedom and emancipation.

In the 1970s: polyester dominated fashion with cheap and colourful fabrics, contributing to the emergence of styles considered “kitsch”.

Today: Kevlar is used not only in personal protection applications, but also for submarine cables and foldable smartphones. Gore-Tex has been used in clothing for space exploration, thanks to a collaboration with NASA. Finally, acrylic is used in LED lighting using textile fibre optics, due to its transparency and lightness.

Where are these fibres to be found in the Quotidian?

In everyday life, these fibres can be found in different areas. In clothing, polyester is commonly used for sweatshirts, nylon for swimwear and elastane for leggings, providing comfort and functionality. In accessories, aramid fibres are used in protective helmets and mobile phones, where they contribute to scratch-resistant screens. In the home, we find acrylic carpets and chlorovinyl curtains, materials prized for their durability and ease of maintenance. Finally, in medicine, polypropylene is used for sutures, while PTFE is used in vascular prostheses due to its biocompatible and resistant properties.

Curiosity

• Nylon Day': it was 15 May 1940, the day DuPont launched nylon stockings, 4 million pairs were sold in just 48 hours in New York, marking a great commercial success and the beginning of nylon's popularity.
• Kevlar and Art: Kevlar has been used in contemporary works of art, such as suspended sculptures, due to its lightness and strength. Artists such as Maya Lin have explored the use of innovative materials, including Kevlar composites, to create art installations.
• Gore-Tex in Pop Culture: Gore-Tex has been mentioned in several films, including The Martian (2015), where astronauts wear clothing made of this material for its waterproof and breathability, essential for survival in extreme environments.
• Polyester in Space: The space suits used during the Apollo 11 mission in 1969 contained layers of thermoregulating polyester, helping to maintain the astronauts' body temperature under extreme conditions in space.

Sustainability and Future Challenges

Synthetic fibres face significant criticism, mainly due to the release of microplastics during washing, which contribute to ocean pollution. It is estimated that around 35% of global microplastics originate from synthetics. However, in the textile industry, production techniques have been developed and refined over the years to minimise the environmental impact of these fibres, thus contributing to greater sustainability.

Among the solutions currently adopted or potentially implementable are washing machine filters, designed to capture microplastics during washing. Furthermore, regenerated polyester, obtained through chemical recycling, is an important innovation, as demonstrated by the Infinited Fiber technology. Finally, bio-based fibres, such as Spider Silk produced by genetically modified bacteria, offer new opportunities to reduce dependence on fossil resources and improve sustainability in the textile sector.

We can say ...
Synthetic fibres, although born out of industrial needs in the 20th century, are now at the centre of a green revolution. These materials, initially developed for their durability and strength, are evolving to meet ecological and sustainable challenges. From diving suits that provide high performance in extreme environments to innovative fabrics designed to save lives, such as those used in medical and emergency settings, their evolution continues to redefine the boundaries between technology and fashion. Recycling initiatives and the development of biodegradable fibres are further contributing to a more sustainable future in textiles.

Innovation and Sustainability

Recycled Polyester (rPET): As mentioned during the writing of this article, one of the major recent developments is the introduction of recycled polyester, which is obtained by recycling plastic bottles and other waste.

This approach, reduces environmental impact, helping to reduce plastic waste; consumes less energy than the production of virgin polyester; promotes a circular economy and responds to the growing demand for environmentally sustainable materials. As a good practice, since the beginning of our activity we have been recycling our production waste, which concerns both natural and synthetic yarns, thanks to third party partners, see also link.

Technological Treatments: New treatments have made polyester and polyamide even better:

• • Antibacterial: Ideal for sportswear and environments where hygiene is paramount.
  • Water-repellent: Perfect for fabrics destined for adverse weather conditions, ensuring greater durability and functionality.

Historical and Political Insights into Synthetic Fibres

Origins & Development

Synthetic fibres, including polyester, originated in the 1940s, when British chemists Whinfield and Dickson developed the first polyester. This period represented a time of great scientific and industrial ferment, especially in the context of post-war reconstruction. The introduction of polyester onto the market marked a real revolution in textile production, as this fibre offered cost-effective solutions and superior performance compared to many natural fibres, such as cotton and silk. Other synthetic fibres, such as nylon and acrylic, were developed during the same period, further expanding the options available to consumers and manufacturers.

Political and Economic Impact

In the years following World War II, synthetic fibres had a significant impact on industrial reconstruction and the spread of “ready-to-wear” fashion, based on mass-produced, ready-to-wear clothing collections. Government policies and economic development strategies in various countries favoured mass production and technological innovation in the textile sector. This has made synthetic fibres, in particular polyester, a key element of global competitiveness, contributing to a rapid expansion of the fashion and clothing industry.

Furthermore, the adoption of synthetic fibres has raised political and environmental issues, as their production and disposal have become a matter of 

Chemical and Physical Properties of Fibre

• Strength and Durability:

  • High Strength: Synthetic fibres, such as polyester and nylon, are known for their high tensile strength. This means that they can withstand weights and stresses without breaking easily.
  • Durability: These fibres are resistant to wear and tear, making them ideal for applications requiring toughness, such as sportswear and outdoor materials.

• Thermal and Chemical Characteristics:

  • Heat Resistance: Synthetic fibres tend to retain their shape even at high temperatures, but may melt or warp when exposed to direct heat. For example, polyester withstands temperatures up to about 150 °C.
  • Resistance to Chemical Agents: Many synthetic fibres are resistant to chemicals such as acids and bases, making them suitable for industrial applications. However, they can be sensitive to organic solvents.

• Resistance to Bending:

  • Low Wrinkle Propensity: Synthetic fibres, such as polyester and acrylic, are designed to resist wrinkling; they do not wrinkle and ironing can be avoided. This makes them ideal for garments that need to maintain a neat and tidy appearance.
  • Ease of Maintenance: Due to their crease resistance, garments made of synthetic fibres require less ironing and are easier to maintain in good condition.

Historical Uses and Contemporary Applications

• Historical Applications: From its beginnings, polyester revolutionised the world of clothing, becoming popular for its practicality and low cost. It was also used in industrial and military environments due to its durability and ease of maintenance.

• Applications in the Everyday: in Sportswear and Outdoor: Due to its quick drying, water repellency and resistance properties, it is widely used in suits, jackets, and technical clothing. in Casual and Fashion: From shirts to suit fabrics, polyester is present in many garments due to its ability to retain its shape and resist wrinkling. Finally for Industrial Applications: it is used in sailing fabrics, biodegradable food packaging and other areas where strength and wear resistance is required.

Curiosities and Comparisons with Other Synthetic Fibres

Other Important Synthetic Fibres:

In addition to polyester, the panorama of synthetic fibres includes materials such as acrylic, aramid fibres (e.g. Kevlar and Nomex), neoprene, polyamide (nylon), polyethylene, polypropylene, Gore-Tex (polytetrafluoroethylene) and polyurethane (Elastam).

These fibres, mainly developed between the 1930s and 1940s, were obtained from petroleum-derived polymers and transformed the textile industry due to their specific properties, such as heat resistance, abrasion protection and waterproof properties.

Because of its versatility, polyester has been the basis for further developments and hybridisations, leading to the creation of “smart” fabrics that can respond to environmental stimuli (e.g. changing colour or breathability according to temperature).

Ongoing research in nanotechnology promises to further improve the properties of polyester by integrating advanced functions such as tissue health monitoring or self-healing capability.

Future perspectives

Current research aims to make synthetic fibres even more sustainable by improving recycling processes and further reducing their environmental impact. The integration of new technologies, such as nanoparticle coatings, aims to create fabrics that are not only durable and functional, but also able to actively interact with their surroundings.

With the evolution of bio-engineering and nanotechnology, synthetic fibres could find uses in as yet undiscovered areas such as wearable electronics and health materials, further expanding its already vast field of applications.

Fun Facts about Synthetic Fibres: Shocks, Bizarre Effects and... Electrostatic Magic!

Why do synthetic fibres give a “shock” when you touch someone?

Lazy electrons are to blame!
Synthetic fibres such as polyester, nylon or acrylic are insulating materials: they do not conduct electricity, so electrons accumulated through friction (e.g. rubbing on the sofa or walking on a carpet) remain trapped on the surface of the fabric. When you touch a person or a conductive object (such as a doorknob), the electrons instantly “jump”, causing the classic shock.

The polyester skirts of the 1970s were notorious for “sticking” to legs from static electricity, creating embarrassing (but amusing) situations. Some pets, such as cats, become “lightning balls” when stroked with synthetic clothing!

Gravity-defying hair

Wearing an acrylic hat or a polyester scarf? After removing it, your hair will turn into an electrostatic work of art, pointing straight up to the sky like antennae.

The magic of “autonomy” socks

Nylon stockings have a nice tendency to slide upwards along the legs, without any human intervention, thanks to the friction generated by the static charge.

Lights and sounds of disco

In a dark room, try slipping on a synthetic wool jumper: you might see small blue sparks and hear a crackling sound (an effect known as triboluminescence).

Why do some fibres load more than others?

It depends on the triboelectric series, a classification that measures how much a material tends to charge when rubbed.

• Static samples: Polyester, nylon, polyethylene (plastics).

• Poorly inclined: natural fibres such as cotton or wool (they absorb moisture, neutralising the charge).

A practical example:
If you wear a polyester sweatshirt and sit on a plastic chair, you become a human pile. The drier the air is (e.g. in winter with the heating on), the more intense the shocks will be!

Pop and Historical Curiosities

• The 1960s and “space” fashion: Synthetic fabrics like argentine (a nylon-metallic blend) were used for futuristic clothes that sparkled... and electrocuted anyone who dared touch them!

• Cult film: In Mary Poppins Returns (2018), Emily Blunt's synthetic fabric dress created so much static during filming that it took her hours to “unload”.

• Music and static: jukeboxes in the 1950s often jammed because people's nylon clothes interfered with the circuits!

How to Neutralise the Electric Battery Effect

• Make the splash move: a spray of water on the fabric reduces the charge.

• Use aluminium foil: rub it on the garment to discharge the electrons (also works with a metal clothes peg).

• Grandmothers' secret: a coin in your pocket “absorbs” static electricity.

Did you know...:
Neoprene (used for diving suits) is so insulating that if you approach a car after wearing it, you could open the door without the keys... thanks to electrostatic discharge!

Synthetic fibres are not only practical, but also a source of everyday “magic”. All it takes is a little moisture or a touch of metal to tame their energy... or enjoy the show!?

If you have further questions or would like to contact us, please leave a comment or write to us!