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Sensors made from ‘electronic spider silk’ printed on human skin (c) Huang Lab, Cambridge
27.05.2024

Sensors made from ‘electronic spider silk’ printed on human skin

Researchers have developed a method to make adaptive and eco-friendly sensors that can be directly and imperceptibly printed onto a wide range of biological surfaces, whether that’s a finger or a flower petal.

The method, developed by researchers from the University of Cambridge, takes its inspiration from spider silk, which can conform and stick to a range of surfaces. These ‘spider silks’ also incorporate bioelectronics, so that different sensing capabilities can be added to the ‘web’.

The fibres, at least 50 times smaller than a human hair, are so lightweight that the researchers printed them directly onto the fluffy seedhead of a dandelion without collapsing its structure. When printed on human skin, the fibre sensors conform to the skin and expose the sweat pores, so the wearer doesn’t detect their presence. Tests of the fibres printed onto a human finger suggest they could be used as continuous health monitors.

Researchers have developed a method to make adaptive and eco-friendly sensors that can be directly and imperceptibly printed onto a wide range of biological surfaces, whether that’s a finger or a flower petal.

The method, developed by researchers from the University of Cambridge, takes its inspiration from spider silk, which can conform and stick to a range of surfaces. These ‘spider silks’ also incorporate bioelectronics, so that different sensing capabilities can be added to the ‘web’.

The fibres, at least 50 times smaller than a human hair, are so lightweight that the researchers printed them directly onto the fluffy seedhead of a dandelion without collapsing its structure. When printed on human skin, the fibre sensors conform to the skin and expose the sweat pores, so the wearer doesn’t detect their presence. Tests of the fibres printed onto a human finger suggest they could be used as continuous health monitors.

This low-waste and low-emission method for augmenting living structures could be used in a range of fields, from healthcare and virtual reality, to electronic textiles and environmental monitoring. The results are reported in the journal Nature Electronics.

Although human skin is remarkably sensitive, augmenting it with electronic sensors could fundamentally change how we interact with the world around us. For example, sensors printed directly onto the skin could be used for continuous health monitoring, for understanding skin sensations, or could improve the sensation of ‘reality’ in gaming or virtual reality application.

While wearable technologies with embedded sensors, such as smartwatches, are widely available, these devices can be uncomfortable, obtrusive and can inhibit the skin’s intrinsic sensations.

Last year, some of the same researchers showed that if the fibres used in smart textiles were coated with materials that can withstand stretching, they could be compatible with conventional weaving processes. Using this technique, they produced a 46-inch woven demonstrator display.

“If you want to accurately sense anything on a biological surface like skin or a leaf, the interface between the device and the surface is vital,” said Professor Yan Yan Shery Huang from Cambridge’s Department of Engineering, who led the research. “We also want bioelectronics that are completely imperceptible to the user, so they don’t in any way interfere with how the user interacts with the world, and we want them to be sustainable and low waste.”

There are multiple methods for making wearable sensors, but these all have drawbacks. Flexible electronics, for example, are normally printed on plastic films that don’t allow gas or moisture to pass through, so it would be like wrapping your skin in cling film. Other researchers have recently developed flexible electronics that are gas-permeable, like artificial skins, but these still interfere with normal sensation, and rely on energy- and waste-intensive manufacturing techniques.

3D printing is another potential route for bioelectronics since it is less wasteful than other production methods, but leads to thicker devices that can interfere with normal behaviour. Spinning electronic fibres results in devices that are imperceptible to the user, but don't have a high degree of sensitivity or sophistication, and they’re difficult to transfer onto the object in question.

Now, the Cambridge-led team has developed a new way of making high-performance bioelectronics that can be customised to a wide range of biological surfaces, from a fingertip to the fluffy seedhead of a dandelion, by printing them directly onto that surface. Their technique takes its inspiration in part from spiders, who create sophisticated and strong web structures adapted to their environment, using minimal material.

The researchers spun their bioelectronic ‘spider silk’ from PEDOT:PSS (a biocompatible conducting polymer), hyaluronic acid and polyethylene oxide. The high-performance fibres were produced from water-based solution at room temperature, which enabled the researchers to control the ‘spinnability’ of the fibres. The researchers then designed an orbital spinning approach to allow the fibres to morph to living surfaces, even down to microstructures such as fingerprints.

Tests of the bioelectronic fibres, on surfaces including human fingers and dandelion seedheads, showed that they provided high-quality sensor performance while being imperceptible to the host.

“Our spinning approach allows the bioelectronic fibres to follow the anatomy of different shapes, at both the micro and macro scale, without the need for any image recognition,” said Andy Wang, the first author of the paper. “It opens up a whole different angle in terms of how sustainable electronics and sensors can be made. It’s a much easier way to produce large area sensors.”

Most high-resolution sensors are made in an industrial cleanroom and require the use of toxic chemicals in a multi-step and energy-intensive fabrication process. The Cambridge-developed sensors can be made anywhere and use a tiny fraction of the energy that regular sensors require.

The bioelectronic fibres, which are repairable, can be simply washed away when they have reached the end of their useful lifetime, and generate less than a single milligram of waste: by comparison, a typical single load of laundry produces between 600 and 1500 milligrams of fibre waste.

“Using our simple fabrication technique, we can put sensors almost anywhere and repair them where and when they need it, without needing a big printing machine or a centralised manufacturing facility,” said Huang. “These sensors can be made on-demand, right where they’re needed, and produce minimal waste and emissions.”

The research was supported in part by the European Research Council, Wellcome, the Royal Society, and the Biotechnology and Biological Sciences Research Council (BBSRC), part of UK Research and Innovation (UKRI).

Source:

Sarah Collins, University of Cambridge

LED Dress Fuses 3D Printing with Futuristic Fashion Photography by Natalie Cartz , Model Perpetua Sermsup Smith, Make-Up Artist Yaying Zheng
20.11.2023

LED Dress Fuses 3D Printing with Futuristic Fashion

  • Designer Anouk Wipprecht Collaborates with Chromatic 3D Materials for a Shining, Motion-Activated Display

Chromatic 3D Materials, a 3D-printing technology company, and high-tech Dutch fashion designer Anouk Wipprecht have unveiled a new futuristic 3D-printed dress that responds to its environment through LEDs. The motion-activated design is among the first garments in the world to directly embed electronics within 3D-printed elastomers. It highlights what the future of creative expression and social interaction may look like as humankind further integrates with technology. Wipprecht’s design was presented at Formnext, the 3D-printing event in Germany.

  • Designer Anouk Wipprecht Collaborates with Chromatic 3D Materials for a Shining, Motion-Activated Display

Chromatic 3D Materials, a 3D-printing technology company, and high-tech Dutch fashion designer Anouk Wipprecht have unveiled a new futuristic 3D-printed dress that responds to its environment through LEDs. The motion-activated design is among the first garments in the world to directly embed electronics within 3D-printed elastomers. It highlights what the future of creative expression and social interaction may look like as humankind further integrates with technology. Wipprecht’s design was presented at Formnext, the 3D-printing event in Germany.

Wipprecht’s avant-garde design highlights the potential of Chromatic’s 3D-printing technology and ChromaFlow 70™ material for commercial use. The designer used 3D printing to adhere nearly 75 flexible, 3D-printed LED domes to the fabric of the dress without adhesive or stitching. That capability could be used to create innovative running apparel, bags, footwear and other products including automotive and aerospace interiors, outdoor recreational equipment and personal protective equipment.  

The unique garment also demonstrates the flexibility of Chromatic’s materials. Unlike other 3D-printed materials, which tend to be brittle and hard, the dress features ChromaFlow 70™, a pliable, heat-resistant material that can drape and stretch more than four times its length without breaking. That flexibility makes it suitable for adding soft and seamless structural, functional and aesthetic elements that are useful for intimate and leisure apparel, sportswear, swimwear and other garments where comfort, silhouette and durability are crucial.

"Using Chromatic’s 3D materials to print offers numerous possibilities for the fashion industry. For designers like me, who incorporate electronics into our creations, it provides a unique opportunity of embedding and securing electronic parts within the printing process,“ says Anouk Wipprecht. “This is my most wearable — and washable — 3D-printed dress yet! As the electronics are enclosed, the material allows me to diffuse my LED lights, and the elastomer is both flexible and strong — making it excellent to bond to fabrics.”

“This collaboration is more than a partnership — it's a vision coming to life. By merging the genius of Anouk Wipprecht with our innovative 3D printing, we're setting the precedent for the future of fashion. We are embarking on a journey that amplifies the boundless integration of tech and art, opening doors for endless possibilities and applications in textiles and fashion,” said Cora Leibig, founder and CEO of Chromatic 3D Materials.

Source:

Chromatic 3D Materials

(c) NC State
07.08.2023

Wearable Connector Technology - Benefits to Military, Medicine and beyond

What comes to mind when you think about “wearable technology?” In 2023, likely a lot, at a time when smartwatches and rings measure heart rates, track exercise and even receive text messages. Your mind might even drift to that “ugly” light-up sweater or costume you saw last Halloween or holiday season.

At the Wilson College of Textiles, though, researchers are hard at work optimizing a truly new-age form of wearable technology that can be proven useful in a wide range of settings, from fashion and sports to augmented reality, the military and medicine.

Currently in its final stages, this grant-funded project could help protect users in critical situations, such as soldiers on the battlefield and patients in hospitals, while simultaneously pushing the boundaries of what textiles research can accomplish.

What comes to mind when you think about “wearable technology?” In 2023, likely a lot, at a time when smartwatches and rings measure heart rates, track exercise and even receive text messages. Your mind might even drift to that “ugly” light-up sweater or costume you saw last Halloween or holiday season.

At the Wilson College of Textiles, though, researchers are hard at work optimizing a truly new-age form of wearable technology that can be proven useful in a wide range of settings, from fashion and sports to augmented reality, the military and medicine.

Currently in its final stages, this grant-funded project could help protect users in critical situations, such as soldiers on the battlefield and patients in hospitals, while simultaneously pushing the boundaries of what textiles research can accomplish.

“The goals set for this research are quite novel to any other literature that exists on wearable connectors” says Shourya Dhatri Lingampally, Wilson College of Textiles graduate student and research assistant involved in the project alongside Wilson College Associate Professor Minyoung Suh.

Ongoing since the fall of 2021, Suh and Lingampally’s work focuses on textile-integrated wearable connectors, a unique, high-tech sort of “bridge” between flexible textiles and external electronic devices. At its essence, the project aims to improve these connectors’ Technology Readiness Level — a key rating used by NASA and the Department of Defense used to assess a particular technology’s maturity.

To do this, Lingampally and her colleagues’ research examines problems that have, in the past, affected the performance of wearable devices.

Sure, these advances may benefit fashion, leading to eccentric shirts, jackets, or accessories — “to light up or change its color based on the wearer’s biometric data,” Lingampally offers — the research has roots in a much deeper mission.

Potential benefits to military, medicine and beyond
The project is funded through more than $200,000 in grant money from Advanced Functional Fabrics of America (AFFOA), a United States Manufacturing Innovation Institute (MII) located in Cambridge, Massachusetts. The mission of AFFOA is to support domestic manufacturing capability to support new technical textile products, such as textile-based wearable technologies.

A key purpose of the research centers around improving the functionality of wearable monitoring devices with which soldiers are sometimes outfitted to monitor the health and safety of their troops remotely.

Similar devices allow doctors and other medical personnel to remotely monitor the health of patients even while away from the bedside.

Though such technology has existed for years, it’s too often required running wires and an overall logistically-unfriendly design. That could soon change.

“We have consolidated the electronic components into a small snap or buckle, making the circuits less obtrusive to the wearer,” Lingampally says, explaining the team’s innovations, which include 3D printing the connector prototypes using stereolithography technology.

“We are trying to optimize the design parameters in order to enhance the electrical and mechanical performance of these connectors,” she adds.

To accomplish their goals, the group collaborated with NC State Department of Electrical and Computer Engineering Assistant Research Professor James Dieffenderfer. The team routed a variety of electrical connections and interconnects like conductive thread, epoxy and solder through textile materials equipped with rigid electronic devices.

They also tested the components for compatibility with standard digital device connections like USB 2.0 and I2C.

Ultimately, Lingampally hopes their work will make wearable technology not only easier and more comfortable to use, but available at a lower price, too.

“I would like to see them scaled, to be mass manufactured, so they can be cost efficient for any industry to use,” she explains.

In a bigger-picture sense, though, her team’s work is reinforcing the far-reaching boundaries of what smart textile research can accomplish; a purpose that stretches far beyond fashion or comfort.

Pushing the boundaries of textiles research
Suh and Lingampally’s work is just the latest breakthrough research originating from the Wilson College of Textiles that’s aimed at solving critical problems in the textile industry and beyond.

“The constant advancements in technology and materials present immense potential for the textile industry to drive positive change across a range of fields from fashion to healthcare and beyond,” Lingampally, a graduate student in the M.S. Textiles program, says, noting the encouragement she feels in her program to pursue innovation and creativity in selecting and advancing her research.

Additionally, in the fiber and polymer science doctoral program, which Suh does research with, candidates focus their research on a seemingly endless array of STEM topics, ranging from forensics to medical textiles, nanotechnology and, indeed, smart wearable technology (just to name a few).

In this case, Suh says, the research lent itself to “unexpected challenges” that required intriguing adaptations “at every corner.” But, ultimately, it led to breakthroughs not previously seen in the wearable technology industry, attracting interest from other researchers outside the university, and private companies, too.

“This project was quite exploratory by nature as there hasn’t been any prior research aiming to the same objectives,” Suh says.

Meanwhile, the team has completed durability and reliability testing on its textile-integrated wearable connectors. Eventually, the group would like to increase the sample size for testing to strengthen and validate the findings. The team also hopes to evaluate new, innovative interconnective techniques, as well as other 3D printing techniques and materials as they work to further advance wearable technologies.

Source:

North Carolina State University, Sean Cudahy

sports Photo Pixabay
21.03.2023

3D-printed insoles measure sole pressure directly in the shoe

  • For sports and physiotherapy alike

Researchers at ETH Zurich, Empa and EPFL are developing a 3D-printed insole with integrated sensors that allows the pressure of the sole to be measured in the shoe and thus during any activity. This helps athletes or patients to determine performance and therapy progress.

In elite sports, fractions of a second sometimes make the difference between victory and defeat. To optimize their performance, athletes use custom-made insoles. But people with musculoskeletal pain also turn to insoles to combat their discomfort.

  • For sports and physiotherapy alike

Researchers at ETH Zurich, Empa and EPFL are developing a 3D-printed insole with integrated sensors that allows the pressure of the sole to be measured in the shoe and thus during any activity. This helps athletes or patients to determine performance and therapy progress.

In elite sports, fractions of a second sometimes make the difference between victory and defeat. To optimize their performance, athletes use custom-made insoles. But people with musculoskeletal pain also turn to insoles to combat their discomfort.

Before specialists can accurately fit such insoles, they must first create a pressure profile of the feet. To this end, athletes or patients have to walk barefoot over pressure-sensitive mats, where they leave their individual footprints. Based on this pressure profile, orthopaedists then create customised insoles by hand. The problem with this approach is that optimisations and adjustments take time. Another disadvantage is that the pressure-sensitive mats allow measurements only in a confined space, but not during workouts or outdoor activities.

Now an invention by a research team from ETH Zurich, Empa and EPFL could greatly improve things. The researchers used 3D printing to produce a customised insole with integrated pressure sensors that can measure the pressure on the sole of the foot directly in the shoe during various activities.

“You can tell from the pressure patterns detected whether someone is walking, running, climbing stairs, or even carrying a heavy load on their back – in which case the pressure shifts more to the heel,” explains co-project leader Gilberto Siqueira, Senior Assistant at Empa and at ETH Complex Materials Laboratory. This makes tedious mat tests a thing of the past. The invention was recently featured in the journal Scientific Reports.

One device, multiple inks
These insoles aren’t just easy to use, they’re also easy to make. They are produced in just one step – including the integrated sensors and conductors – using a single 3D printer, called an extruder.

For printing, the researchers use various inks developed specifically for this application. As the basis for the insole, the materials scientists use a mixture of silicone and cellulose nanoparticles.
Next, they print the conductors on this first layer using a conductive ink containing silver. They then print the sensors on the conductors in individual places using ink that contains carbon black. The sensors aren’t distributed at random: they are placed exactly where the foot sole pressure is greatest. To protect the sensors and conductors, the researchers coat them with another layer of silicone.

An initial difficulty was to achieve good adhesion between the different material layers. The researchers resolved this by treating the surface of the silicone layers with hot plasma.
As sensors for measuring normal and shear forces, they use piezo components, which convert mechanical pressure into electrical signals. In addition, the researchers have built an interface into the sole for reading out the generated data.

Running data soon to be read out wirelessly
Tests showed the researchers that the additively manufactured insole works well. “So with data analysis, we can actually identify different activities based on which sensors responded and how strong that response was,” Siqueira says.

At the moment, Siqueira and his colleagues still need a cable connection to read out the data; to this end, they have installed a contact on the side of the insole. One of the next development steps, he says, will be to create a wireless connection. “However, reading out the data hasn’t been the main focus of our work so far.”

In the future, 3D-printed insoles with integrated sensors could be used by athletes or in physiotherapy, for example to measure training or therapy progress. Based on such measurement data, training plans can then be adjusted and permanent shoe insoles with different hard and soft zones can be produced using 3D printing.

Although Siqueira believes there is strong market potential for their product, especially in elite sports, his team hasn’t yet taken any steps towards commercialisation.

Researchers from Empa, ETH Zurich and EPFL were involved in the development of the insole. EPFL researcher Danick Briand coordinated the project, and his group supplied the sensors, while the ETH and Empa researchers developed the inks and the printing platform. Also involved in the project were the Lausanne University Hospital (CHUV) and orthopaedics company Numo. The project was funded by the ETH Domain’s Advanced Manufacturing Strategic Focus Areas programme.

Source:

Peter Rüegg, ETH Zürich

(c) DITF
20.12.2022

New 3D printing process for sustainable fiber composite components

Nature works often with fiber composites. The construction principles of nature require little material and energy and thus ensure the survival of animals and plant species. Examples include wood, plant stalks, chitinous shells, bones or tissues such as tendons and skin. Mussel shells or spider silk are also composite tissues. We can take advantage of these principles to design and manufacture bio-based, sustainable fiber reinforced composites, which are currently in high demand. Bio-based fiber reinforced composites consist of natural fibers or cellulose fibers embedded in a bio-based matrix. The bio-based components offer properties comparable to those of commonly used glass fiber composites. The German Institutes of Textile and Fiber Research (DITF), together with Arburg GmbH + Co KG, are developing an energy- and material-efficient 3D printing process for manufacturing of such lightweight bio-based fiber composites.

Nature works often with fiber composites. The construction principles of nature require little material and energy and thus ensure the survival of animals and plant species. Examples include wood, plant stalks, chitinous shells, bones or tissues such as tendons and skin. Mussel shells or spider silk are also composite tissues. We can take advantage of these principles to design and manufacture bio-based, sustainable fiber reinforced composites, which are currently in high demand. Bio-based fiber reinforced composites consist of natural fibers or cellulose fibers embedded in a bio-based matrix. The bio-based components offer properties comparable to those of commonly used glass fiber composites. The German Institutes of Textile and Fiber Research (DITF), together with Arburg GmbH + Co KG, are developing an energy- and material-efficient 3D printing process for manufacturing of such lightweight bio-based fiber composites.

In fiber composites, which occur naturally, reinforcing fibers such as collagen or cellulose fibrils are embedded in a matrix of lignin, hemicellulose or collagen. The fiber strands align with the stress patterns. Tissues are formed mostly via solution-based physio-chemical processes that take place at ambient temperature. Similar to nature, new 3D printing processes with continuous fiber reinforcement also allow the deposition of fiber strands in the right place (topology optimization) and in the appropriate direction in accordance to the load. However, natural fibers such as cellulose fibers are sensitive to higher temperatures. Therefore, they cannot be processed in the commonly employed thermoplastic 3D printing process.

The result of the research work is 3D-printed fiber composite components consisting of cellulose continuous fibers embedded in a cellulose-based matrix. Newly developed 3D-printing process enables to manufacture the composites at ambient temperature. This means that - as in nature - the material and component can be produced simultaneously in a single operation at ambient temperature.

The cellulose fiber strand is first stabilized with a binder for processing in the printer. The specially designed print head transforms the binder into a matrix with which the cellulose continuous fibers are encased. Since the cellulose fibers and the matrix have similar chemical structures, the composite component is particularly stable. The mechanical properties, such as breaking strength, are exceptionally good. The solution-based and energy-efficient manufacturing method developed by the research team can also be used in other composite materials manufacturing processes. It is particularly suitable for processing temperature-sensitive materials that are in high demand, such as natural or cellulose fibers.

The " CellLoes-3D-Druck" research project is funded by the German Federal Ministry of Education and Research as part of the "Biologisierung der Technik" ideas competition.

Source:

Deutsche Institute für Textil- und Faserforschung Denkendorf

Image: Gaharwar Laboratory
13.12.2022

New inks for 3D-printable wearable bioelectronics

Flexible electronics have enabled the design of sensors, actuators, microfluidics and electronics on flexible, conformal and/or stretchable sublayers for wearable, implantable or ingestible applications. However, these devices have very different mechanical and biological properties when compared to human tissue and thus cannot be integrated with the human body.

A team of researchers at Texas A&M University has developed a new class of biomaterial inks that mimic native characteristics of highly conductive human tissue, much like skin, which are essential for the ink to be used in 3D printing.

This biomaterial ink leverages a new class of 2D nanomaterials known as molybdenum disulfide (MoS2). The thin-layered structure of MoS2 contains defect centers to make it chemically active and, combined with modified gelatin to obtain a flexible hydrogel, comparable to the structure of Jell-O.

Flexible electronics have enabled the design of sensors, actuators, microfluidics and electronics on flexible, conformal and/or stretchable sublayers for wearable, implantable or ingestible applications. However, these devices have very different mechanical and biological properties when compared to human tissue and thus cannot be integrated with the human body.

A team of researchers at Texas A&M University has developed a new class of biomaterial inks that mimic native characteristics of highly conductive human tissue, much like skin, which are essential for the ink to be used in 3D printing.

This biomaterial ink leverages a new class of 2D nanomaterials known as molybdenum disulfide (MoS2). The thin-layered structure of MoS2 contains defect centers to make it chemically active and, combined with modified gelatin to obtain a flexible hydrogel, comparable to the structure of Jell-O.

“The impact of this work is far-reaching in 3D printing,” said Dr. Akhilesh Gaharwar, associate professor in the Department of Biomedical Engineering and Presidential Impact Fellow. “This newly designed hydrogel ink is highly biocompatible and electrically conductive, paving the way for the next generation of wearable and implantable bioelectronics.”1 

The ink has shear-thinning properties that decrease in viscosity as force increases, so it is solid inside the tube but flows more like a liquid when squeezed, similar to ketchup or toothpaste. The team incorporated these electrically conductive nanomaterials within a modified gelatin to make a hydrogel ink with characteristics that are essential for designing ink conducive to 3D printing.

“These 3D-printed devices are extremely elastomeric and can be compressed, bent or twisted without breaking,” said Kaivalya Deo, graduate student in the biomedical engineering department and lead author of the paper. “In addition, these devices are electronically active, enabling them to monitor dynamic human motion and paving the way for continuous motion monitoring.”

In order to 3D print the ink, researchers in the Gaharwar Laboratory designed a cost-effective, open-source, multi-head 3D bioprinter that is fully functional and customizable, running on open-source tools and freeware. This also allows any researcher to build 3D bioprinters tailored to fit their own research needs.

The electrically conductive 3D-printed hydrogel ink can create complex 3D circuits and is not limited to planar designs, allowing researchers to make customizable bioelectronics tailored to patient-specific requirements.

In utilizing these 3D printers, Deo was able to print electrically active and stretchable electronic devices. These devices demonstrate extraordinary strain-sensing capabilities and can be used for engineering customizable monitoring systems. This also opens up new possibilities for designing stretchable sensors with integrated microelectronic components.

One of the potential applications of the new ink is in 3D printing electronic tattoos for patients with Parkinson’s disease. Researchers envision that this printed e-tattoo can monitor a patient’s movement, including tremors.

This project is in collaboration with Dr. Anthony Guiseppi-Elie, vice president of academic affairs and workforce development at Tri-County Technical College in South Carolina, and Dr. Limei Tian, assistant professor of biomedical engineering at Texas A&M.
This study was funded by the National Institute of Biomedical Imaging and Bioengineering, the National Institute of Neurological Disorders and Stroke and the Texas A&M University President’s Excellence Fund. A provisional patent on this technology has been filed in association with the Texas A&M Engineering Experiment Station.

1 This study was published in ACS Nano.

Source:

Alleynah Veatch Cofas, Texas A & M University

First tests with free-form tiles made of wood short fiber filament. (Photo: LZH) Photo: LZH. First tests with free-form tiles made of wood short fiber filament.
19.09.2022

Sustainability in 3D Printing: Components made of Natural Fibers

3D printing has been in use in architecture for a while, and now it is to become ecologically sustainable as well: Together with partners, the LZH is researching how to produce individual building elements from natural fibers using additive manufacturing.

3D printing has been in use in architecture for a while, and now it is to become ecologically sustainable as well: Together with partners, the LZH is researching how to produce individual building elements from natural fibers using additive manufacturing.

In the project 3DNaturDruck, architectural components such as facade elements shall be created from natural fiber-reinforced biopolymers in 3D printing. To this end, the scientists will develop the corresponding composite materials from biopolymers with both natural short fibers and natural continuous fibers and optimize them for processing with the additive manufacturing process FDM (Fused Deposition Modeling). The project partners' goal is to enable smart and innovative designs that are both ecological and sustainable.
 
The goal: highly developed components made from sustainable materials
Within the project, different natural fiber-reinforced biopolymer composites will be investigated. The partners are researching both processing methods with very short natural fibers, such as from wood and straw, and a method for printing continuous fibers from hemp and flax in combination with biopolymers. The LZH then develops processes for these new materials and adapts the tools and nozzle geometries of the FDM printer. A pavilion with the 3D-printed facade elements is planned as a demonstrator on the campus of the University of Stuttgart.
 
The project partners want to explore how additive manufacturing can be used to simplify manufacturing processes for architectural components. Natural fiber-reinforced biopolymers are particularly suitable for producing components with complex geometries in just a few steps and with low material and cost requirements. With their research, the partners are also working on completely new starting conditions for the fabrication of newly developed architectural components: For example, the topology optimization of components according to their structural stress can be easily implemented with additive manufacturing.

Enabling the natural fiber trend in architecture also using additive manufacturing
There is great interest in the use of natural fibers in structural components in architecture and construction because natural fibers have several advantages. They have good mechanical properties combined with low weight and are widely available. As a renewable resource with in some cases very short renewal cycles, they are also clearly a better ecological alternative than synthetic fibers.

In additive manufacturing, large-format elements for the architectural sector have so far mostly been manufactured with polymers based on fossil raw materials. Research in the project 3DNaturDruck should now make the use of natural fibers in architecture possible for additive manufacturing as well.

About 3DNaturDruck
The project 3DNaturDruck is about the design and fabrication of 3D-printed components made of biocomposites using filaments with continuous and short natural fibers.

The project is coordinated by the Department of Biobased Materials and Materials Cycles in Architecture (BioMat) at the Institute of Building Structures and Structural Design (ITKE) at the University of Stuttgart. In addition to the LZH, project partners include the Fraunhofer Institute for Wood Research Wilhelm-Klauditz-Institut (WKI) and the industrial companies Rapid Prototyping Technologie GmbH (Gifhorn), ETS Extrusionstechnik (Mücheln), 3dk.berlin (Berlin) and ATMAT Sp. Z o.o. (Krakow, Poland).

The project is funded by the German Federal Ministry of Food and Agriculture through the Fachagentur Nachwachsende Rohstoffe e.V. under the funding code 2220NR295C.

Source:

Laser Zentrum Hannover e.V.

Graphik: Pixabay
11.01.2022

FIMATEC innovation network enters second funding phase

The network for the development of fiber materials technology for healthcare and sports will receive funding from the Central Innovation Programme for SMEs (ZIM) for another two years.

The Federal Ministry for Economic Affairs and Climate Action (BMWi) approved a corresponding application in December 2021. This will continue to provide funding for the development of innovative functional fibers, smart textiles and application-optimized fiber composite materials until June 2023 and strengthen the technological competitiveness and innovative strength of small and medium-sized enterprises (SMEs).

The network for the development of fiber materials technology for healthcare and sports will receive funding from the Central Innovation Programme for SMEs (ZIM) for another two years.

The Federal Ministry for Economic Affairs and Climate Action (BMWi) approved a corresponding application in December 2021. This will continue to provide funding for the development of innovative functional fibers, smart textiles and application-optimized fiber composite materials until June 2023 and strengthen the technological competitiveness and innovative strength of small and medium-sized enterprises (SMEs).

For this purpose, the FIMATEC innovation network combines competences from different engineering and scientific disciplines with small and medium-sized manufacturers and service providers from the target sectors in medicine and sports (e.g. orthopaedics, prosthetics, surgery, smart textiles) as well as players from the textile and plastics industry.      

This interdisciplinary combination of industrial partners and application-oriented research institutions increases competitiveness and enables the players to realise their technical research and development projects quickly and in a targeted manner. The focus for the joint R&D projects of the companies and research institutions is on the development of innovative materials and efficient manufacturing technologies. 
          
Fiber-based materials have become indispensable in many applications in medicine and sports. As a pure fiber, processed into a textile or as a fiber composite plastic, they offer an almost unlimited variety for adjusting property and functional profiles. At the same time, the demands on the range of functions, performance and cost-effectiveness are constantly increasing, so that there is great potential for innovation. Developments are driven on the one hand by new materials and manufacturing processes, and on the other by innovative applications. Products with new and superior functions create a technological advantage over international competitors and enable higher sales revenues. In addition, efficient processes, application-optimized materials or even the integration of functions into the basic structure of textile materials lead to lower production costs and improved marketing opportunities in the future.
For developments in this context, the partners have joined forces in the FIMATEC innovation network, thus combining their expertise. Within the network, innovative materials and processes are being developed jointly in the following areas and tested in future-oriented products and services:

  • Functional fibers
    Innovative fiber materials with integrated functionalities
  • Preforming
    Highly load path optimized fiber orientations for complex fiber composite components.    
  • Smart Textiles
    Textile-based sensors and actuators
  • Hybrid material and manufacturing technologies
    Application-optimized components through cross-technology solution approaches.    
  • Fiber composites  
    Intelligent matrix systems and function-optimized fiber materials.    
  • Fiber-reinforced 3D printing  
    High-quality additive manufacturing processes for the efficient production of individualized products.

 
17 network partners are researching fiber-based materials for medical and sports technologyCurrently, ten companies and seven research institutions are involved in FIMATEC. Interested companies and research institutions as well as potential users can continue to participate in the cooperation network or R&D projects. In the course of membership, the partners are actively supported in identifying and initiating innovation projects as well as securing financing through funding acquisition. One application for ZIM project funding has already been approved by FIMATEC in its first year.

The aim of the already approved project "CFKadapt" is to develop a thermoformable fiber-plastic composite material for optimally adaptable orthopedic aids such as prostheses and orthoses. In the "Modul3Rad" project, which is currently being worked out in detail, the project partners intend to develop a modular lightweight frame system for the construction of user-friendly therapy tricycles, suitable for everyday use by severely and very severely disabled children. Three further collaborative projects are already in the planning stage.

The technology and knowledge transfer enables in particular small and medium-sized enterprises (SMEs) to access cutting-edge technological research, especially these are often denied access to innovations due to the lack of their own research departments. The IWS GmbH has taken over the network management for FIMATEC and supports the partners from the first idea to the search for suitable project partners and the preparation and coordination of funding applications. The aim is to obtain funding from the Central Innovation Programme for SMEs (ZIM), which offers companies funding opportunities for a wide range of technical innovation projects in cooperation with research institutions.

FIMATEC-netzwork partners
all ahead composites GmbH | Veitshöchheim | www.bike-ahead-composites.de
Altropol Kunststoff GmbH | Stockelsdorf | www.altropol.de
Diondo GmbH | Hattingen | www.diondo.com
Mailinger innovative fiber solutions GmbH | Sontra | www.mailinger.de
Sanitätshaus Manfred Klein GmbH & Co. KG | Stade | www.klein-sanitaetshaus.de
STREHL GmbH & Co KG | Bremervörde | www.rehastrehl.de
WESOM Textil GmbH | Olbersdorf | www.wesom-textil.de
Faserinstitut Bremen e.V. (FIBRE) | www.faserinstitut.de
E.F.M. GmbH | Olbersdorf | www.efm-gmbh.de
REHA-OT Lüneburg Melchior und Fittkau GmbH | Olbersdorf | www.rehaot.de
Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung IFAM | Bremen | www.ifam.fraunhofer.de
Leibniz-Institut für Polymerforschung Dresden e.V. (IPF) | www.ipfdd.de
Institut für Polymertechnologien Wismar e.V. (IPT) | www.ipt-wismar.de
Institut für Verbundwerkstoffe GmbH | Kaiserslautern | www.ivw.uni-kl.de

Associated network partners
9T Labs AG | Zürich, Schweiz | www.9tlabs.com
Fachhochschule Nordwestschweiz, Institut für Kunststofftechnik (FHNW) | www.fhnw.ch
KATZ - Kunststoff Ausbildungs- und Technologie-Zentrum | Aarau, Schweiz | www.katz.ch

Source:

Textination / IWS Innovations- und Wissensstrategien GmbH

Cotton (c) pixabay
10.11.2020

Fashion and textiles industry keen to go green despite COVID-19 pandemic

  • New research shows business leaders at top fashion, retail and textile businesses are putting sustaina-bility drive first, despite COVID-19 pandemic
  • The power of data in the effort to ‘go green’ is well recognized, but patchy performance suggests more access to better quality data needed to help turbocharge change
  • Despite Covid-19, fashion leaders are confident that fast, affordable and sustainable fashion is realistic, with crisis seen as opportunity to recharge sustainability efforts 

New research reveals the extent of the global fashion industry's commitment to sustainability, despite the COVID-19 pandemic, with sustainability ranked as the second most important strategic objective for businesses in the sector .

  • New research shows business leaders at top fashion, retail and textile businesses are putting sustaina-bility drive first, despite COVID-19 pandemic
  • The power of data in the effort to ‘go green’ is well recognized, but patchy performance suggests more access to better quality data needed to help turbocharge change
  • Despite Covid-19, fashion leaders are confident that fast, affordable and sustainable fashion is realistic, with crisis seen as opportunity to recharge sustainability efforts 

New research reveals the extent of the global fashion industry's commitment to sustainability, despite the COVID-19 pandemic, with sustainability ranked as the second most important strategic objective for businesses in the sector .

The new research, from the U.S. Cotton Trust Protocol and the Economist Intelligence Unit (EIU), is like Puma, H&M and Adidas. Explored in a new report, ‘Is Sustainability in Fashion?’ the research comes at a time when the industry finds itself at a crossroads: whether to continue to invest in sustainability, or row back in light of the pandemic.

Sustainability is business critical, say fashion, retail and textile leaders  
In defiance of the pandemic, the new data shows that for many of the world's biggest brands, sustaina-bility is now business critical. The majority of fashion, retail and textile leaders surveyed (60%), named implementing sustainability measures as a top two strategic objective for their business, second only to improving customers’ experience (ranked first by 64%). This contrasts starkly with the fewer than one in six (14%) that listed 'rewarding shareholders' as a top objective.

Leaders report they’re introducing sustainability measures throughout the supply chain, from sourcing sustainably produced raw materials (65%), introducing a circular economy approach to their business and cutting greenhouse gasses (51% apiece) and investing in new technologies like 3D printing and blockchain (41%).  Overall, the majority (73%) were optimistic that sustainable, fast and affordable fash-ion is achievable.

Data matters
A key finding of the research is that data matters for sustainability. When asked what measures they were implementing today to be more sustainable, collecting data from across the business and in the supply chain to measure performance was listed at the very top of business leaders’ list of priorities by 53%, second only to developing and implementing an environmental sustainability strategy with meas-urable targets, favoured by almost six in ten (58%).

And data is not important for the immediate term only –  three in ten (29%) said the availability of relia-ble data holds the key to greater sustainability over the next decade, while almost three-quarters of industry leaders (73%) stated their support for global benchmarks and thresholds as an effective means of measuring sustainability performance and driving progress in the industry.

But data collection is patchy
However, although brands clearly recognize the importance of data, the research’s findings on data collection indicates that top fashion brands, retailers and textile businesses may find sourcing good quality data a challenge.

While business leaders report relatively high rates of data collection on supplier sustainability practices based on a survey of 150 leading executives from top fashion, retail and textile business across Europe and the US and interviews with leading brands (65%) and worker rights and workplace health and safety in the supply chain (62%), a significant proportion (45%) of businesses do not track greenhouse gas emissions across production, manufacturing and distribution of the products they sell, while 41% don’t track the amount of water and energy being used to produce the raw materials they source.

Looking to the future, over a quarter (26%) of respondents saw a lack of available, easily-accessible data as hampering collaboration on sustainability across the industry. As some respondents in interview pointed out, while collecting data could be hard it is important.  

Commenting on the findings, Gary Adams, President of the U.S. Cotton Trust Protocol, said: "It is clear that brands are faced with a challenge on driving forward their sustainability efforts. At the U.S. Cotton Trust Protocol we know that accurate, reliable data supports businesses in this work - providing not only the evidence to show hard work and progress, but the insight to drive further improvements. We pro-vide one of the most robust data collection mechanisms available for an essential material – cotton – for unparalleled transparency.”  

Partnership offers path to further progress
An additional key finding is that fashion, retail and textile business clearly cannot drive change in isola-tion: collaboration is needed. According to one respondent, from Reformation, this is already happen-ing. “We’re energized to see collaboration and cooperation across the industry and believe that will only increase over time.”

However, when it comes to external support to help guide that progress, business leaders do not nec-essarily perceive further regulation as the answer.  The UN Sustainable Development Goals (SDGs) and government regulation were each given equal weight in driving sustainability change, both cited by a quarter of respondents (24% apiece). Regulatory requirements were also ranked by only a third (33%) of the business leaders surveyed as being within the top three factors that will drive sustainability pro-gress over the next decade.  

Jonathan Birdwell, Regional Head of Public Policy and Thought Leadership, The Economist Intelligence Unit: “It’s clear from the survey results and our interviews with business leaders that the industry is committed to driving progress on its sustainability performance. We were particularly struck by the fact that sustainability is largely considered as pre-competitive – behind the scenes brands are sharing re-sources and lessons learned.”

The impact of Covid-19  
This determination on sustainability flies in the face of COVID-19 uncertainty, although when asked their view on the pandemic, just over half (54%) of respondents said they thought it would make sustainabil-ity less of a priority within the industry.

The U.S. Cotton Trust Protocol is a new initiative that sets a new standard in sustainably grown cotton. By working closely with growers, the U.S. Trust Protocol provides clear, consistent data on six key sus-tainability metrics, including GHG emissions, water use, soil carbon, soil loss, independently audited through Control Union Certification. For the first time, brands can access annualized farm level data and trace their cotton from field to 'laydown'.

Research based on quantitative survey of 150 executives in the fashion, retail and textile industry based in Europe and the United States undertaken by the Economist Intelligence Unit between 9th July and 28th July 2020. The survey was complemented by qualitative insight from interviews with ten professionals in the fashion and sustainability space.

Protective masks for Augsburg University Hospital (c) Fraunhofer IGCV
14.04.2020

Protective equipment from 3d printers

  • Fraunhofer IGCV supplies protective equipment made via 3d printers to university hospital Augsburg

For more than a week, the Institute for Materials Resource Management at the University of Augsburg has been supplying the University Hospital Augsburg with protective masks from 3D printers. In order to meet the enormous demand for absolutely necessary protective equipment for the the needs of hospital staff, a call for support was sent to cooperation partners - Augsburg University of Applied Sciences and Fraunhofer IGCV are stepping in.
 

  • Fraunhofer IGCV supplies protective equipment made via 3d printers to university hospital Augsburg

For more than a week, the Institute for Materials Resource Management at the University of Augsburg has been supplying the University Hospital Augsburg with protective masks from 3D printers. In order to meet the enormous demand for absolutely necessary protective equipment for the the needs of hospital staff, a call for support was sent to cooperation partners - Augsburg University of Applied Sciences and Fraunhofer IGCV are stepping in.
 

Fast communication in the research network:
Production of 3D-printed parts accelerates in the shortest possible time
Without further ado, an internal university group searched for possibilities of manufacturing via 3D printing. Prof. Dr. Markus Sause and Prof. Dr. Kay Weidenmann of the Institute for Materials Resource Management at the University of Augsburg immediately agreed and pulled out all the stops to start production as quickly as possible. In order to provide as many protective masks as possible in the shortest possible time, an appeal was also made to existing cooperation partners. They found what they were looking for in their direct colleague Prof. Dr. Johannes Schilp, Professor of Production Informatics at the University of Augsburg and Head of the Processing Technology Department at the Augsburg Fraunhofer IGCV: Max Horn, research associate at the Fraunhofer Institute, and Paul Dolezal from the FabLab (production laboratory) at Augsburg University of Applied Sciences immediately promised their help. "Thanks to the excellent cooperation of our team, the first parts were produced in our laboratory for additive manufacturing just a few hours after the first telephone call," Max Horn recalls. "With the support of the Augsburg University of Applied Sciences and the Fraunhofer IGCV, the production capacity of 50 masks per day could be significantly increased," Markus Sause is pleased to report.
          

Printing masks with Fused Deposition Modeling (FDM)
Fused Deposition Modeling (FDM) was selected as the manufacturing process for the face protection. This means that the mask is created by forcing fusible plastic through a nozzle and applying it in layers in individual lanes. In addition to an extensive laboratory for metal-based additive manufacturing, the Fraunhofer IGCV operates a new laboratory unit with various FDM printers. Due to the simplicity of the process and its great flexibility, it is particularly suitable for prototypes and sample components. "However, the masks produced are by no means only illustrative objects", adds Georg Schlick, Head of the Components and Processes Department at the Fraunhofer IGCV. The team processed durable polymers for the parts, which have good resistance to the disinfectants used in the hospital. This results in high-quality components that are ideally suited for multiple use.
 
Additive manufacturing for flexible production
In the meantime, some bottlenecks have been overcome: The Institute for Materials Resource Management at the University of Augsburg is switching back to production processes for the manufacture of face masks that are better suited for the production of large quantities. "The great strength of additive manufacturing lies rather in the production of very complex components with smaller quantities," explains Matthias Schmitt, group leader for additive manufacturing at the Fraunhofer IGCV. "But 3D printing also enables us to act at very short notice and to compensate for lack of capacity for almost any component as required," Schmitt continues. Thanks to the flexibility, motivation and expertise of all cooperation partners, a complete production and supply chain for the face masks was implemented within a few days. Georg Schlick therefore emphasizes the need for good networking and rapid exchange between the research institutions. "The close networking within the 3D printing community enables short communication channels and fast action. This can save lives in this case."

Source:

Fraunhofer Institute for Casting, Composite and Processing Technology IGCV

The new AddiTex compound comes out of the extruder as a filament for 3D printing. © Fraunhofer UMSICHT
12.11.2019

FRAUNHOFER UMSICHT: COMPOUNDS FOR ADDITIVE MANUFACTURING, GEOTEXTILES AND WEARABLES

Whether biodegradable geotextiles, wearables from thermoplastic elastomers or functional textiles from 3D printers - the scope of plastics developed at the Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT is wide.

Insights into these projects were provided from October 16th - 23rd  in Düsseldorf: At the K, scientists presented their work on thermally and electrically conductive, biodegradable, bio-based compounds as well as compounds suitable for additive production.
 
Textile composites from the 3D printer
In the "AddiTex" project, plastics were developed that are applied to textiles in layers using 3D printing and give them functional properties. A special challenge in the development was the permanent adhesion: The printed plastic had to be both a strong bond with the textile and sufficiently flexible to be able to participate in movements and twists.

Whether biodegradable geotextiles, wearables from thermoplastic elastomers or functional textiles from 3D printers - the scope of plastics developed at the Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT is wide.

Insights into these projects were provided from October 16th - 23rd  in Düsseldorf: At the K, scientists presented their work on thermally and electrically conductive, biodegradable, bio-based compounds as well as compounds suitable for additive production.
 
Textile composites from the 3D printer
In the "AddiTex" project, plastics were developed that are applied to textiles in layers using 3D printing and give them functional properties. A special challenge in the development was the permanent adhesion: The printed plastic had to be both a strong bond with the textile and sufficiently flexible to be able to participate in movements and twists.

A flexible and flame-retardant compound was developed, which is particularly suitable for use in the field of textile sun and sound insulation, as well as a rigid compound, which is used, among other things, for reinforcing the shape of protective and functional clothing.

Geotextile filter for technical-biological bank protection
Geotextile filters for technical-biological bank protection are the focus of the "Bioshoreline" project. It stands for gradually biodegradable nonwovens, which allow a near-natural bank design of inland waterways with plants. They consist of renewable raw materials and are intended to stabilize the soil in the shore area until the plant roots have grown sufficiently and take over both filter and retention functions. The ageing and biodegradation of the fleeces begin immediately after installation, until the fleeces are gradually completely degraded.

Prototypes of the geotextile filters are currently being tested. Female scientists evaluate the plant mass formed above and below ground with and without geotextile filters as well as the influence of the soil type on plant growth and the biological degradation of the filter.

Wearables made of thermoplastic elastomers
In addition, Fraunhofer UMSICHT is developing novel, electrically conductive and flexible compounds that can be processed into thermoplastic-based bipolar plates. These plastics are highly electrically conductive, flexible, mechanically stable, gas-tight and chemically resistant and - depending on the degree of filling of electrically conductive additives - can be used in many different ways. For example, in electrochemical storage tanks (batteries), in energy converters (fuel cells), in chemical-resistant heat exchangers or as resistance heating elements.

Another possible field of application for these plastics: Wearables. These portable materials can be produced easily and cheaply with the new compounds. It is conceivable, for example, to form garments such as a vest by means of resistance heating elements. The idea behind this is called Power-to-Heat and enables the direct conversion of energy into heat.

FUNDING NOTES

"AddiTex" is funded with a grant from the State of North Rhine-Westphalia using funds from the European Regional Development Fund (ERDF) 2014-2020 "Investments in growth and employment". Project Management Agency: LeitmarktAgentur.NRW – Projektmanagement Jülich.

The "Bioshoreline" project (funding reference: 22000815) is funded by the Federal Ministry of Food and Agriculture (BMEL) on the basis of a resolution of the German Bundestag.

More information:
Fraunhofer-Institute UMSICHT K 2019
Source:

Fraunhofer Institute for Environmental, Safety, and Energy Technology UMSICHT

Textildruckerei Mayer: Innovation management in Swabian © Textildruckerei Heinrich Mayer GmbH
03.09.2019

CEO Michael Steidle (Textildruckerei Mayer): Innovation Management in Swabian

  • “Keep it up! is not an option"

The textile printing company Mayer is a family business on the Swabian Alb. As a leader in textile printing, in screen, rouleaux, rotary, sublimation and flock printing and as well as in 3D coating, the enterprise is increasingly applying its leading expertise to the field of technical textiles. An in-house quality management system ensures the traceability of all production processes, an environmental portfolio the efficient use of energy, sustainability and resources. Textination talked to Managing Director Michael Steidle.

  • “Keep it up! is not an option"

The textile printing company Mayer is a family business on the Swabian Alb. As a leader in textile printing, in screen, rouleaux, rotary, sublimation and flock printing and as well as in 3D coating, the enterprise is increasingly applying its leading expertise to the field of technical textiles. An in-house quality management system ensures the traceability of all production processes, an environmental portfolio the efficient use of energy, sustainability and resources. Textination talked to Managing Director Michael Steidle.

Textildruckerei Heinrich Mayer GmbH is a family business that has been active in textile printing and finishing for 45 years. If you had to introduce yourself in 100 words to someone who doesn't know the company, what makes you unique?
Over the past ten years or so, our family-owned company based in rural Baden-Wurttemberg has changed from a classic textile printing company into a system supplier. A central precondition for this is our knowledge of our own strengths. We rely on proven printing solutions. We do not rush into exchanging them with the latest trend. Instead, we examine whether another, innovative application can be found for them. Or whether one it is possible to combine the tried and tested with a new approach. For example, we were able to solve electronic requirements by printing technology. This area is our second focus. I am a Master of electronic engineering and completed my apprenticeship at Bizerba, a worldwide leading specialist in industrial weighing and labeling technologies. My wife brought me to the textile industry.

In which product area do market and customers challenge you in particular? And on which socially relevant areas do you see a particularly great need for innovation in the upcoming 10 years? What is your assessment that textile finishing will be able to offer solutions?
Mobility is an issue that will be of great concern to all of us in the coming years. In this area trump is what brings little weight, can be produced in a resource-saving way and is easy to shape. All these requirements are met by textile carrier materials and composites. However, textiles as a pure material are still not well-known in public and in our target industries. This understanding should be promoted.

Were fashion and clothing yesterday and do hybrid product developments like your ceramic-coated high-tech fabrics represent the future? When would the company name have to be adjusted, and how long will you keep your broad range of products and services?
In any case, it is true that the textile market, especially the clothing sector, is becoming smaller and smaller in Germany, while the market for technical textile solutions is growing. Of course, this also has an impact on our business and our priorities. Textiles are now found in so many products - we would never have dreamed about before!

As far as the company name is concerned, we have discussed it extensively. We decided to keep it because it is still right. The textiles we talk about are mostly a functional material, but they still remain textiles. And the technology with which we manufacture our high-tech coatings continues to be the printing technology ...

"Without innovation no future" - In five years time, you celebrate the company’s 50th anniversary, with which fundamental corporate decisions will you then have secured the future of your customers and employees?
You already mentioned the landmark decision: "Innovation, innovation, innovation." We can secure our future through innovation only. This means that we must constantly question ourselves and be prepared to be widely interested in attending trade fairs and exhibitions and find out what people are looking for.

Innovation manager or tinkering: What does it mean for a medium-sized family business high up on the Swabian Alb having to profile on specialties in the niche? What advantages do you see compared to large companies?
The Swabian Alb is a traditional textile region. In 1980, about 30,000 people worked here in the textile industry. In 2005 it was barely a sixth. There is not much else left to do than to look for profitable niches and to show a clear profile. Perhaps the special thing about it is that we are not alone in this. Basically, all successful textile companies in our region have undergone a similar process.

As a small - and owner-managed - company, we have the shortest and fastest decision-making channels. That makes us more flexible than a big company. A budget is not questioned five times, but it is decided. If we make a trial, we can evaluate it in the evening and react the very next day. If something doesn't work, we don't need a meeting – then that's it.

At the same time, we do not automatically have a budget for research and development. We first have to carve this out elsewhere. And we do so in the knowledge that it can also be for the trash can. Within the framework of this budget, entrepreneurs have the greatest possible freedom.

To break new ground means decisiveness, overcoming fears - and thus the courage to fail. Not every project can succeed. Which entrepreneurial decision are you particularly glad to have made in retrospect? What makes you proud?
That's easy (Michael Steidle laughs)! We have realized a company’s request that has driven us for months, which in the end has also awakened personal ambition. That was the introduction to these technical coatings, the key and door opener for technical textiles in general. In doing so, I revived old resources, almost by chance. Meaning: my knowledge in electronics. That's when I realized that with a textile you can do completely different things. When you see the finished product on sale after two or three years, it makes the whole team proud!

Every man for himself, God for us all: With which sectors in the textile industry and from neighboring sectors do you want to get closer cooperation beyond competitive borders? For which higher-level problems do you consider this to be indispensable?
Actually, it is not so much a matter of competitive boundaries - cooperation with innovative competitors would always be good for the end product, but that is the case in every industry!

For us, cooperation with other companies in the textile chain is important, i.e. the upstream company. Let’s assume that I am looking for a special fabric for my coating, which in turn has to be made from a special yarn. Then I am already dependent on two companies. Fortunately, we have innovative companies right on our doorstep. But sometimes we have to go further to find the right partner. Characteristics such as willingness to take risks, a common entrepreneurial interest and a passion for the final product are enormously important in a successful cooperation.

Together with your customers, universities, specialist institutes and research institutes, porject-related you work on market-ready solutions. Do you think Germany is a good breeding ground for innovative entrepreneurs? What should happen to stay successful in international competition?
The cooperation with the institutes makes perfect sense; after all, it is their task to carry out research for companies that cannot shoulder such assignments on their own. This includes testing facilities as well as applying for funding, which is only possible in cooperation with research institutes. However, they are public institutions and therefore per se have a different objective than a company: We need to bring a promising idea to market as soon as possible so that it generates a return. A research institute does not have this pressure.

And Germany as a location? Germany is a brilliant location! But we have an infrastructure bottleneck: I mean roads and internet connections as well as access to funding or venture capital. That does not exist in Germany in the true sense anyway. Finding investors for an idea is therefore extremely difficult.

Let me give you an example: Over the years, I have received around 14,000 euros in subsidies for a coating innovation. An American entrepreneur had a very similar idea. He was able to raise about $ 35 million within three years through venture capital, crowd funding, and grants. In the end, he did not even know what he should spend the whole money on!

In addition, for us as a company in Germany, the large, open economic area of Europe is important!

You are the first textile printing company to be certified for screen printing as well as for rotary and rouleaux printing according to the GOTS standard. How important do you consider such certification as a unique selling point in the competition?
Such certifications are important because we work with clients in the upper and premium segments. Especially in times in which - undoubtedly justified - ever greater demands are placed on sustainable business and also the external presentation receives a steadily growing attention, we can support our clients this way. We therefore offer different printing methods, all of which are certified. One thing we have to be aware of is, that if we - and all the other members of the textile chain – charge the additional costs, the price mark-up would be so enormous that nobody would accept it anymore.

How do you feel about the willingness to perform of the succeeding generation? And who would you recommend to join the textile industry and to whom would you dissuade from it?
We work a lot with students and interns. Every year we give two students the opportunity to work and research in our company for their master's thesis. With these young talents, we often experience great commitment and the ambition to bring their own project to a meaningful completion. At the same time, it is difficult for us to fill our apprenticeships; the idea of working eight hours daily, five days a week seems daunting.

And who would I recommend to join the textile industry? For decades, we vehemently discouraged our offspring from working in the textile industry, because one said it has no future ... As a true high-tech industry, it is interesting for engineers, process engineers, chemists or electronic engenieers. Very important: for people with visions! If you are looking for the classic textile industry you have to be prepared to work worldwide and you will not be unemployed. Many companies are desperately looking for plant managers or managing directors for their non-European branches.

 

EuroShop 2017 © Messe Duesseldorf / ctillmann
18.10.2016

EUROSHOP 2017 – DISPLAY MANNEQUINS: REAL MOOD BOOSTERS!

  • Visual marketing increases in importance for offline retail in view of e-Commerce competitors
  • Display mannequins are in focus for this
  • Emotionalising is decisive
  • Individuality and flexibility are also demanded
  • There is a shift towards semi-abstract mannequins with regional and genre differences
  • Proportion of customised mannequins is rising
  • Sustainability remains an issue

EuroShop is one of those trade fairs always teeming with visual highlights. Guaranteed to present a special treat here is, of course, the Visual Merchandising Hall, the exhibition place of display mannequins and store window decorations. March 2017 will see Hall 11 of Düsseldorf Exhibition Centre (instead of Hall 4 previously), become a POS experience guaranteed to attract plenty of attention.

  • Visual marketing increases in importance for offline retail in view of e-Commerce competitors
  • Display mannequins are in focus for this
  • Emotionalising is decisive
  • Individuality and flexibility are also demanded
  • There is a shift towards semi-abstract mannequins with regional and genre differences
  • Proportion of customised mannequins is rising
  • Sustainability remains an issue

EuroShop is one of those trade fairs always teeming with visual highlights. Guaranteed to present a special treat here is, of course, the Visual Merchandising Hall, the exhibition place of display mannequins and store window decorations. March 2017 will see Hall 11 of Düsseldorf Exhibition Centre (instead of Hall 4 previously), become a POS experience guaranteed to attract plenty of attention. After all, in view of the e-Commerce competition, visual marketing and the resulting emotional, personalised appearance will become more and more important for bricks-and-mortar retailers. “Consumers’ emotional needs will become the overriding theme for EuroShop,” says Andreas Gesswein, CEO of Genesis Display from Auetal, with conviction.

Display mannequins hold special emotionalising potential. It is not by chance that Düsseldorf visual artist Domagoj Mrsic once presented them as “super heroes” in one of his stagings - as Superman and Wonder Woman, Batman and Catwoman, Spiderman and Spiderwoman. Provided the displays are done well mannequins are in a way real heroes. With their appearance, their posture, gestures and mimics they can really breathe life into shop windows and in-store decorations, serve as sales-promoting tools or arouse empathy, interest and curiosity. And if they are not just headless and very abstract they even give retail stores and brands a profile and signature style. With the power of their poses they send out a clear signal as to which target group is addressed, which degree of fashion and price range is served. Moreover, when arranged in groups, they can serve as story-tellers for passers-by. Unforgettable was the “Ugly’s” line of mannequins by supplier Hans Boodt, which mimicked “real-life” men rather than V-shaped boys with six packs. It included both a long, tall one and a short, fat one dressed in passion-killing underwear. “The new generation of mannequins will say more about the brand. They will participate in communicating more about each brand’s essential values and set them apart from the competition”, says Jean-Marc Mesguich, CEO of Window France headquartered in Carros.

The portfolio offered by the display mannequin industry is wide and varied: in addition to top-model lookalikes it features plus-size beauties, Europeans, Africans and Asians, the afore-mentioned super heroes and funny common people. Kissing couples feature alongside sumo wrestlers. In line with the motto "don't take yourself too seriously", vendors have long also included dogs and cats; and even chameleons since many mannequins prove to be true artists of disguise. “Cameleon”, for example, is a patented concept of Window France: Hundreds of eyes and lips are available to chose from, eye-lashes can be glued on, wigs attached/detached, different make-ups applied or the whole face can be replaced with the help of magnets – in brief, all it takes to ensure a constantly refreshed POS appearance. Add to this what is by now a huge range of colours and materials: surfaces from velvet and rubber are just as common these days as are metallic varnishes or concrete and copper coatings.     

In view of what has been presented over the past few years you may wonder what might come next. Although the majority of fashion retailers and brands have not nearly exploited the full potential already available today. In the past few years abstract mannequins were in highest demand. “They are fit for many applications and easy to handle, since no wigs or make-up have to be styled,” says Andreas Gesswein (Genesis Display) accounting for reasons and adds: “But they are also easier to copy and therefore available in every price segment.” In practice, efficiency sometimes clearly “overrides” emotion. “But when stores do not stand out with the image they project they do not prompt shoppers to enter either,” says Jean-Marc Mesguich (Window France). And for EuroShop 2017 Window France will definitely have far more in store than “exciting variations of the abstract theme”.

Faces are back again

The fact is: just like the fashion they are wearing, display mannequins follow trends. Triggered by a desire to cut a sharper profile and stronger expression, industry insiders have seen a trend towards semi-abstract mannequins. “A face is at least alluded to. Mannequins are less neutral and it becomes visible: Retailers want to make a statement again showing their true colours. There is a trend towards addressing target groups with a more high-profile message,” explains Cornel Klugmann, Country Manager for the D-A-CH region at Hans Boodt from the Dutch city of Zwijndrecht. Monica Ceruti, in charge of PR & Communication at Almax from Mariano Comense/Italy, agrees: “It is true that demand for abstract mannequins continues to be high but there is a clear trend towards more realistic facial characteristics. This includes such details as the application of eyelashes or wigs. And dynamic postures are also getting more popular again.”

Andreas Gesswein (Genesis Display) remarks: “Especially in the luxury segment we are registering stronger demand for more realistic mannequins with faces and emotional facial expressions that brands are looking for to stand out from the rest.” A trend that Jean-Marc Mesguich (Window France) confirms: “The Haute Couture brands have already abandoned the egghead in exchange for something that will have more impact and - more importantly - get people talking about their brand.” He adds: “The growing trend of viewing fashion and fashion windows online is pushing brands to make more attractive windows and to change their displays on a more regular basis.”

The days of faceless “eggheads” seem to be over. And above and beyond this? “The look and feel is becoming more and more high-end. White and grey are replacing darker shades, glossy replaces matt and aspirational looks with more charisma are more in demand,” says Cornel Klugmann (Hans Boodt). Monica Ceruti (Almax) sees great potential in “handcrafted looks”. This means torsos with and without arms with different materials for the individual components – pedestal, torso and head – and wood as well as metallic surfaces all set the tone here. Sabrina Ciofi from Design Office La Rosa from Palazzolo Milanese/Italy summarises the “principal themes of tomorrow” as follows: “Customers demand high product quality, the right price, maximum after-sales service and high product flexibility and/or diversity.” This statement should be valid across national borders. Otherwise she says despite all the globalisation: “There are as many trends as there are markets.” Monica Ceruti (Almax) concretized: “In Europe and the USA the differences are not fundamental. In the Middle East, however, mannequins without realistic traits continue to be in demand for religious and cultural reasons. This applies especially to female display mannequins.”

Customised becomes cheaper

Producers report that the percentage of customised mannequins is generally rising. These display mannequins are individually and exclusively manufactured to customers’ specifications. In this way retail companies and brands can stand out from their competitors and consistently leverage their CI. At Hans Boodt, for example, the proportion of customised mannequins is now said to be as high as 75%. And thanks to cost-cutting process optimisation it is expected to rise even further. Like Window France these Dutch vendors have now discovered 3D printing which can serve their purposes and their buyers. While in the past prototypes used to be elaborately modelled by sculptors in clay, these can now be “printed” in a time and cost-saving manner. “On top of this, the process is even more true to life and detailed,” delights Cornel Klugmann (Hans Boodt). Graphic designers create the desired mannequins with CAD systems where all the details can be freely configured. Then the files are uploaded to the printer that puts them into practice 1:1. “We can respond to trends so much faster and at the end of the day also design more new collections each year”, Klugmann explains further benefits. Jean-Marc Mesguich (Window France) adds: “Thanks to 3D we can create mannequins that really correspond to each and every brand and every brand’s precise image, to be perfectly in-sync with their public. This is an important evolution in the role that mannequins play.”

Alongside process optimisation sustainability remains important for the sector. “The fashion sector is now highly aware of this topic and attaches importance to its suppliers also complying with the relevant criteria,” explains Monica Ceruti (Almax).   The other market players polled also share this view. For La Rosa, whose mannequins are exclusively designed and manufactured in Italy, sustainability is an integral part of quality. By their own accounts, the Italians have analysed the whole life cycle of their mannequins with a view to minimising their ecological footprint. Almost half of the polystyrene used, they say, is recycled which saves substantial amounts of crude oil and carbon dioxide emissions. On top of this, La Rosa takes back its products after use and re-introduces them into the material cycle. Production operations work with a carbon-capture system, the cooling towers use process water, energy is generated by the company’s own PV park. Andreas Gesswein (Genesis Display) also underscores the importance of this topic: “Our customers focus on trust, honesty and partnership-based cooperation. And this includes providing evidence of sustainability rather than copying other peoples’ marketing straplines. In cooperation with Dupont Tate and Lyle BioProducts we have increased the percentage of biomass in our mannequins even further over the past few years, just the same way we constantly check and optimise our materials, packaging and transport routes for sustainability.” Hans Boodt is also opting for an interesting avenue. The company currently studies whether ocean plastics could be used as a raw material for production.

EuroShop as an opportunity of the future

The display mannequin market is and will be in motion – both on the supply and demand sides. “There are customers who buy their mannequins cheaply online and others who are interested in top quality, professional consulting and holistic visual-merchandising concepts,” explain Andreas Gesswein (Genesis Display) and Cornel Klugmann (Hans Boodt). There should be no doubt about who they expect to be more successful. Andreas Gesswein: “The challenges are enormous. 2016 has been especially challenging for fashion retailers, also in Asia and the USA. Companies are faced with changed market and shopper behaviours. EuroShop 2017 will therefore probably be one of the most important ones since the fair's inception.” Jean-Marc Mesguich emphasizes: “I think that it is essential to be present at EuroShop. For both suppliers and clients. It is a sure way of exchanging views and helps pave the way forward for both parties. This year we are at a turning point in the market, so it will be even more useful for everyone.” Cornel Klugmann also recommends retail representatives to visit the trade fair: “Our innovative power is the opportunity for the future.”
 
EuroShop 2017 will be open to visitors daily from Sunday 5 March 2017 to Thursday 9 March 2015, 10:00 am to 6:00 pm. A day ticket is EUR 70 (EUR 50 for an e-ticket, purchased online in advance), 2-day ticket EUR 90 (e-ticket: EUR 70) and a 4-day ticket EUR 150 (e-ticket: EUR 130). Entrance tickets include free trips to and from EuroShop on all trains, buses and trams within the networks of the VRR transport authority (Verkehrsverbund-Rhein-Ruhr).

 

Shoes must glitter in winter 2016/17 © Messe Düsseldorf GmbH / ctillmann
16.02.2016

SHOES MUST GLITTER IN WINTER 2016/17

Paint, glitter and metallic effects should provide the highlights at the foot in the coming autumn / winter 2016/2017. In addition, deep shades of red and the trend color cognac and camel. Otherwise it is said: more volume, more profile. Androgenic shoe types conquer the shoe racks.

Paint, glitter and metallic effects should provide the highlights at the foot in the coming autumn / winter 2016/2017. In addition, deep shades of red and the trend color cognac and camel. Otherwise it is said: more volume, more profile. Androgenic shoe types conquer the shoe racks.

While the chilly autumn weather in September and in the first half of October still brought good sales for winter shoes and boots, the mild November and December thwart the retailers bill. Especially snow shoes and boots became shop keepers at many places, especially small and medium size enterprises had to record a decline in sales. Although the online trade had to fight with the same weather conditions, initial figures however indicate, that the online shoe trade was able to register last year a sales growth of around seven percent. The stationary trade is looking for new concepts, is even more intensely dealing with its assortments and suppliers and aims to react therefore with a proper weighting of new footwear trends. Many traders took advantage of the just ended GDS shoe fair in Dusseldorf in order to learn about the new trends for autumn / winter 2016/17: The hippie look with its inspirations from the 1970s finds its continuation. Folkloric elements are implemented with much attention to details: fringe, fur, embroidery and patchwork will be found not only on shoes but on boots as well. Velvets, animal prints, tapestry, floral or abstract patterns enhance the detail-note of the theme. Snake prints are found not only subtly used as an ornament, but all over the entire shoe. Pumps and ballerinas are interpreted feminine with curved heels. Hip, although probably not a bringer of numbers, the overknee, to be carried with the tunic dress.

Trendy remain androgynous types of footwear such as Budapest, Broques, Monks and Loafer, that are perfectly suited to types of trousers as the culotte and the new over long pants. Their soles are partly very distinctive but extremely light. Loving details such as perforations, tassels, straps ensure modernity. The new bootees convince thru reduced optics and different shaft heights: They range from almost ankledeep over classic variants to medium-high boots which are worn narrow to the leg. Copped and round boot strips stay, new are square forms. At heels block-heels and slightly tapered shapes are in vogue, the soles are ultra-light and come in their fashionable variants as plateau or wedge soles.

The sneaker is an indispensable part of the shoe closets and remains unbeatable in the coming autumn / winter. In the new season it will appear cleaner and with fewer details. Tone in tone leo, metallics and suede will be mixed with a little paint, which gives the new sneakers an extravagant touch. Matt-gloss and 3D effects give the sneakers a high fashion look. For the colder months the sneaker comes in a material mix with fur and a warm interior design. Neoprene, mesh and leather produce in combination with 3D printing a new trendy image. Side zipper, damping and padding ensure greater comfort. For the soles lightweight, flexible PU or mix variants remain important. Fashionably are darker soles or soles in a dirty look in addition to the white and light soils.

In the new season the classic black and will not disappear from the shoe cabinets, even though black will not be traded as the ultimate trend color in the new season. Buying impulses should be given by stone, timber and mineral tones as well as cognac and camel, rust and deep shades of red and khaki, olive and denim tones. Color gradients and strong contrasts create a new appearance. Gloss and glitter are back in the trend, through glittering colors as well as through pearls and strass.

The choice of materials by the designers for the new shoe fashion is versatile as seldom before, they like to mix in the new season: animated, soft qualities with haptic and structure, next to very clean, smooth qualities. It will be patched, stitched, printed, embossed, patterned and flocked. The trendy shoe materials include leather qualities in natural optics, often with noticeable grain pattern. Lizard embossments are back in vogue, especially crocodile and python. Soft suede and nubuck qualities are a must. Exceptional finish effects and fantasy embossments are very trendy. 3D is not just an issue for new high-tech qualities,
but can also be seen as brocade, bouclé, lace or jacquard pattern.