3D Printed Textile Composites Development for Wearable Product Applications

Abstract

The purpose of this study was to explore the development process of 3D printed textile composites and examine potential of this new material for wearable product application. The specific objectives were to: (a) identify commonly used filament-textile combinations by pairing filaments for 3D printing with conventional textile substrates, (b) develop 3D printed textile composites using the Fused Deposition Modeling method by optimizing key design features to enhance printability, (c) examine the material properties of 3D printed textile composites through objective material evaluation, and (d) assess users’ sensorial perceptions of these newly developed materials through subjective material evaluation.

This study was conducted in two phases. Study 1 focused on the development of 3D printed textile composites. Based on a literature review, one filament for 3D printing and five conventional textile substrates were identified and paired, resulting in five commonly used filament-textile combinations for developing 3D printed textile composites. The 3D printed textile composite samples across five filament-textile combinations were created using a 3D printer, with geometric features and printing parameters optimized to improve printability. Study 2 was the evaluation of 3D printed textile composites through objective and subjective material analyses. The objective evaluation examined the effects of filament-textile combinations on adhesion strength, bendability, elongation, and drapability, as well as the impact of 3D printed layer deposition on bendability, elongation, and drapability of 3D printed textile composites compared with their corresponding conventional textiles. The subjective evaluation, involving 26 participants, assessed users’ sensorial perceptions of 3D printed textile composites, specifically perceived temperature, surface properties, flexural properties, and bulk properties, across different filament-textile combinations, and compared these perceptions with those of the corresponding conventional textiles.

The results of Study 1 indicated that thermoplastic polyurethane paired with knitted cotton, woven cotton, knitted polyester, woven polyester, and polyester mesh represent commonly used filament-textile combinations used by designers and researchers in the development of 3D printed textile composites for wearable applications. The findings also demonstrated that geometric features and printing parameters significantly influence the printability and overall quality of 3D printed textile composites during the 3D modeling and printing process. The results of Study 2 further revealed that the 3D printed layer deposition process significantly affects both the material properties and users’ sensorial perceptions of 3D printed textile composites compared with their corresponding conventional textiles. Additionally, the findings indicated that variations in filament-textile combinations lead to distinct mechanical performances and users’ perceived sensorial characteristics.

This study contributed to the development of 3D printed textile composites for wearable products in several ways. First, it proposed a comprehensive integrated theoretical framework and provided practical guidelines for designers to optimize the material development process, thereby improving the printability and overall quality of 3D printed textile composites. Second, the study identified and examined commonly used filament-textile combinations, offering valuable insights for designers in selecting appropriate filaments for 3D printing and conventional textile substrates to achieve optimized mechanical performance. Third, the study deepened the understanding of the 3D printed layer deposition process and its impact on both mechanical behavior and users’ sensorial perceptions. These findings highlight the strong potential of 3D printed textile composites as wearable materials in wearable product design, enabling designers to intentionally control material properties and users’ sensorial properties.

In summary, this study is original, unique, and innovative in addressing important gaps in the literature as one of the few comprehensive scientific studies devoted to systematically developing, evaluating, and applying 3D printed textile composites for wearable product applications. This study advances the growing field of 3D printed wearable product design by deepening the understanding of the development process, mechanical performance, and users’ sensorial perceptions of 3D printed textile composites. Ultimately, the findings further expand the potential of 3DP in the apparel and textiles industry, laying the groundwork for future innovations in 3D printed textile development and next-generation wearable technologies.