Fabrication of plasticized interpenetrating polymer network (IPN) leatherette derived from bacterial cellulose and silicon dioxide using a novel 2-in-1 thickening process

The negative consequences of fast fashion have heightened concerns about the fashion industry’s sustainability. Bacterial Cellulose (BC) has emerged as a promising biomaterial for sustainable applications in textiles and leather. However, dehydrated BC’s low thickness and high stiffness pose limitations, reducing its appeal in diverse fields, including fashion, healthcare, etc. To address this challenge, a Plasticized BC-based interpenetrating polymer network (IPN) leatherette is investigated using an innovative 2-in-1 thickening process and a following softening step using Glycerol. The thickening process involves a novel “self-thickening” technique based on cellulosic mercerization and a formation of interpenetrating polymer network structure using BC and Silica skeleton. The fabricated BC-based material exhibits unique IPN structure and significant increase in BC thickness to 1.83±0.10 mm ( \(\approx\) $\approx$ 16.64 times thicker), areal density to 2034.46±37.58 \(\hbox {g/m}^{2}\) ${\text{g/m}}^2$ ( \(\approx\) $\approx$ 16.33 times denser), moisture content of 31.09±0.48%, moisture regain of 45.12±1.01%, flexural rigidity of 3291.29±100.88 \(\upmu\) $\mathrm{\mu }$ Nm, and improved bending modulus of 6.48±0.20 MPa ( \(\approx\) $\approx$ 1035.27 times lower) compared to those of untreated BC. Furthermore, the durability of the Plasticized BC-based IPN leatherette is evaluated through five washing cycles, with the material retaining approximately 75.96%, 66.61%, 82.98%, and 77.39% of its unwashed thickness, areal density, moisture content, and regain, respectively. This study contributes to the value of BC-based materials in the textile and leather industries, offering a sustainable alternative to existing materials and production processes. Moreover, developing this novel 2-in-1 thickening process establishes a foundation for future research on BC functionalization in various applications, thereby contributing to sustainable development.