Large-Scale Nanofiber Manufacturing| Recent Advances in Next-Generation Textiles

Donghua University Academician Yu Jianyong and Professor Ding Bin's AM Review: Latest Advances in Next-Generation Textiles

Background: Textiles have played a pivotal role in human development, evolving from basic fibers to complex multifunctional materials. Advances in materials science, nanotechnology, and electronics have propelled next-generation textiles beyond traditional functions, unlocking innovative possibilities for various applications. Thermal management textiles combine ultra-light, ultra-thin insulating layers with adaptive cooling technologies to optimize temperature regulation in dynamic and extreme environments. Moisture management textiles utilize advanced structural unidirectional transport and breathable membranes to ensure exceptional comfort in sportswear and outdoor gear. Protective textiles feature enhanced functionalities including antibacterial, antiviral, antigas, heat-resistant and radiation shielding capabilities, providing high-performance solutions for healthcare, defense and hazardous industries. Interactive textiles integrate sensors for monitoring physical, chemical and electrophysiological parameters, enabling real-time data collection and response to various environmental and user-generated stimuli. Energy textiles utilize triboelectric, piezoelectric and hydroelectric effects to improve energy harvesting and storage in wearable devices. These advancements position next-generation textiles at the forefront of materials science, significantly expanding their potential across broad applications. However, challenges remain including the development of novel textile structures, enhancement of textile performance, and multifunctional integration across different fields. These factors will determine future directions in next-generation textile R&D across various domains.

Based on this, Donghua University Academician Yu Jianyong and Professor Ding Bin published a review covering recent advances in next-generation textiles, analyzing various functional types, current challenges, and future prospects. The related research was published in Advanced Materials under the title "Recent Advances in Next-Generation Textiles".

Figure 1. A brief overview of the topics discussed in next-generation textiles, including schematic diagrams of: thermal management textiles, moisture management textiles, protective textiles, interactive textiles, energy harvesting and storage textiles, and light-emitting display textiles.

Figure 2. a) Schematic diagram illustrating the heat transfer mechanism of porous aerogel. b) Photograph showing fibrous aerogel standing on a flower petal. c) Infrared image of a human arm covered with aerogel and down fiber filling. d) Real-time temperature of aerogel and three other samples covering a human arm. e) Relationship between thermal conductivity and bulk density for different fiber materials. f) Microstructure of the super fabric. g) Microstructure of the thin film. h) Image demonstrating the thermal insulation performance and passive radiative heating capability of the super fabric. i) Infrared image of a volunteer exposed to 10°C frontal wind at 3 m/s for 5 minutes. j) Temperature difference of skin simulators under different fabric samples at the same position. k) Comparison of thermal insulation performance versus thickness between different thermal management materials and the super fabric under dark conditions.

Figure 3. a) Schematic diagram of thermal-regulating textiles. b) Skin temperature of mannequins coated with cotton and DCT fabrics. c) Comparison of BNNS content and thermal conductivity between DCT and previously reported BNNS fiber materials. d) Schematic of water vapor adsorption in fabrics. e) Outdoor measurement curves showing moisture content, solar radiation intensity and relative humidity versus time during fabric absorption-desorption cycles. f) Summary of water desorption rates for reported composite desiccants at different desorption temperatures. g) Schematic of super-fabric for daytime radiative cooling. h) Mid-infrared emissivity of fabric, polymethylpentene and silver nanowires. i) Temperature tracking of skin covered with different fabrics under direct sunlight in Guangzhou.

Figure 4. a) Schematic of the human-body-clothing-environment system showing heat input and dissipation. b) Photograph of a mannequin wearing an LNT vest and corresponding infrared image after 30 minutes of sunlight exposure. c) Thermal comfort zones of bare skin, conventional textiles, and dual-mode textiles. d) Cooling performance comparison between nanofiber textiles and other textiles. e) Heating performance comparison between nanofiber textiles and other textiles. f) Water-responsive wool knitwear for thermoregulation: providing cooling during perspiration and warmth when skin is dry. g) Simulated monthly energy savings (red for heating mode, blue for cooling mode) and annual total savings (green) of dual-mode devices in Tianjin region. h) Temperature variation of simulated skin covered with thermoregulatory textiles in changing environments. i) Comparative analysis of thermoregulatory clothing performance including net power, thermal comfort zone expansion, skin cooling capacity, bidirectional thermoregulation, and adaptive capability against representative works reported in literature.

Figure 5. a) Schematic of perspiration process in biomimetic porous membranes. b) Illustration of superimposed capillary pressure differences driving anti-gravity water penetration and extensive diffusion in composite porous membranes. Moisture management tester results for porous membranes with water supply through c) PLA-TF layer and d) MFC-TF layer. e) Moisture management capability and R-values of representative fabrics. f) Waterproof mechanism of nanofiber membranes based on Laplace's law. g) Contact angles and hydrostatic pressure of membranes with different liquids. h) Comparison of waterproof/breathable performance between nanofiber membranes and other microporous WBMs. i) Performance comparison of waterproof/breathable properties between nanofiber membranes and commercial membranes.

Figure 6. a) Thermal insulation mechanism of LCAs. b) Schematic diagram of the excellent thermomechanical stability of LCAs. c) Additional tortuous solid conduction paths in bilayer hexagonal boron nitride aerogels (hBNAGs). d) Relationship between room-temperature thermal conductivity and operating temperature for aerogel-like materials in air. e) Comparison of thermal conductivity and maximum operating temperature among various aerogel-like materials. f) Optical photographs demonstrating the compressive resilience of aerogels in alcohol lamp flame (500°C) and liquid nitrogen (-196°C), along with SEM image of aerogel after carbonization at 1600°C. g) Comprehensive performance comparison between LCAs and other aerogel materials.

Summary and Outlook: Addressing these challenges from an application perspective will be crucial in the coming decade. Key issues include material development, device integration, continuous production methods, standardization and scalability. The development of biocompatible materials is essential to ensure the safety and comfort of wearable textiles, particularly in medical and health monitoring applications.

1. In thermal management textiles, innovations such as ultra-thin insulation and adaptive cooling fabrics show great potential for reducing personal energy consumption. However, achieving long-term durability without compromising flexibility and functionality remains a significant challenge. A comprehensive approach is needed to balance lightweight design with robust thermal performance, especially in applications like sportswear, military uniforms and everyday clothing.

2. Significant progress has been made in developing fabrics that can dynamically transport moisture while ensuring breathability and water resistance. Yet maintaining optimal balance between these properties without sacrificing comfort or long-term usability is a key challenge. Future research should focus on improving the microstructure design of these textiles to enhance adaptability to different environmental conditions while increasing durability and scalability for widespread applications.

3. Protective textiles with advanced functions like antibacterial, antitoxin, radiation shielding and thermal insulation meet essential needs in healthcare, defense and hazardous industries. However, challenges related to comfort, weight and durability persist. Standardization of these protective features is crucial to ensure consistent performance across different applications and industries.

4. Interactive textiles represent a paradigm shift in wearable technology by enabling garments to monitor health parameters and respond to environmental stimuli. However, these technologies remain in their infancy. Significant progress is needed in optimizing sensor integration, improving energy efficiency, and minimizing the impact of electronics on textile comfort and flexibility. Ensuring durability during wear while maintaining sensor accuracy and responsiveness remains a key challenge.

5. Energy-harvesting and storage textiles offer innovative solutions for powering wearables but face efficiency limitations and challenges in integrating reliable energy storage systems. Understanding the dynamic behavior and physicochemical properties of material interfaces is crucial for improving charge generation and transfer efficiency.

6. Light-emitting display textiles have unique applications in safety equipment, fashion and real-time information display. However, challenges such as achieving optimal resolution and efficiency persist. The development of next-generation textiles should prioritize scalability, durability and biocompatibility to facilitate broader commercialization and practical applications. Advancing scalable manufacturing processes like automated weaving and 3D knitting technologies is necessary to meet growing demand for smart textiles. Improving durability and washability is also critical, especially for textiles integrating wearable electronics. Furthermore, exploring innovative weaving integration methods could lead to new textile functionalities and enhanced performance. By addressing these challenges, next-generation textiles can enhance personal comfort while enabling diverse applications in energy management, healthcare and other fields, promoting multifunctional integration with improved mechanical durability and resilience.