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<p>The rapid rise of textile waste, driven by fast fashion and linear manufacturing models, poses significant environmental concerns and leads to materials loss through disposal by landfilling or incineration. This study aims to identify a suitable nonwoven composite (NCs) fabrication method using mechanically recycled synthetic textile fibres. To achieve this aim, composites were developed from a 50/50 wt% blend of recycled fibres (RF) and low melting polyester (LMP). Nonwoven preforms were produced via carding and pre-pressing, followed by four hot-pressing techniques that combined preform drying before hot-pressing and a 1-minute relaxation period during hot-pressing. Three pressing temperatures (110&#xa0;°C, 120&#xa0;°C, and 130&#xa0;°C) were applied. Mechanical properties were evaluated through tensile, flexural, and Charpy impact tests. The results showed that incorporating 1-minute relaxation period during hot pressing improved tensile strength by approximately 23%, flexural strength by 16%, and impact strength by 11%. The highest tensile and flexural strength values were observed at 130&#xa0;°C, while the maximum impact strength was achieved at 110&#xa0;°C. Drying the nonwoven preforms prior to pressing reduced tensile, flexural and impact properties. The developed NCs exhibited mechanical properties demonstrating potential for semi-structural applications, including furniture components and lightweight automotive interior panels. These findings support the adoption of circular economy practices in the textile industry and contribute to sustainable waste management strategies.</p>

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Effect of Processing Parameters on the Properties of Nonwoven Composites Developed from Mechanically Recycled Textile Fibres

  • 期刊论文

  • 发表日期：

    2026年8月3日

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  • Md Toufiqur Rahman,
  • Tiia Plamus,
  • Anti Rohumaa,
  • Urve Kallavus

摘要

The rapid rise of textile waste, driven by fast fashion and linear manufacturing models, poses significant environmental concerns and leads to materials loss through disposal by landfilling or incineration. This study aims to identify a suitable nonwoven composite (NCs) fabrication method using mechanically recycled synthetic textile fibres. To achieve this aim, composites were developed from a 50/50 wt% blend of recycled fibres (RF) and low melting polyester (LMP). Nonwoven preforms were produced via carding and pre-pressing, followed by four hot-pressing techniques that combined preform drying before hot-pressing and a 1-minute relaxation period during hot-pressing. Three pressing temperatures (110 °C, 120 °C, and 130 °C) were applied. Mechanical properties were evaluated through tensile, flexural, and Charpy impact tests. The results showed that incorporating 1-minute relaxation period during hot pressing improved tensile strength by approximately 23%, flexural strength by 16%, and impact strength by 11%. The highest tensile and flexural strength values were observed at 130 °C, while the maximum impact strength was achieved at 110 °C. Drying the nonwoven preforms prior to pressing reduced tensile, flexural and impact properties. The developed NCs exhibited mechanical properties demonstrating potential for semi-structural applications, including furniture components and lightweight automotive interior panels. These findings support the adoption of circular economy practices in the textile industry and contribute to sustainable waste management strategies.