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L. M. Haverhals et al.
platform [1, 2] that has its roots in the discoveries of IL efficacy towards biopolymers—notably by Swatloski and Rogers [3], as well as Trulove, DeLong, and Mantz
[4]. NFW is peerless as it develops efficient manufacturing processes for highperformance composite materials using abundant natural materials while preserving
complex structures that are unique to natural materials [5–7]. Using tunable IL-based
chemistries, NFW is pioneering fast, scalable fabrication processes that solve systemic problems within large industries. For example, NFW has patented processes
that achieve zero-waste indigo dyeing while simultaneously recycling “waste“ cotton
fiber into denim fabrics [8]. In this chapter, we will discuss several examples of how
fabrication through welding fiber fills important manufacturing gaps and is poised to
provide renewable, biodegradable natural materials that outperform petroleum-based
plastic incumbents across many types of applications.
It is well known and documented that petroleum-based synthetics are simultaneously wonderful and terrible [9]. This is particularly obvious within the textile
industry where, during the past 60+ years, humanity has become increasingly reliant
on petroleum-based synthetic plastics [10]. Presently, the textile industry uses around
100 billion pounds of polyester annually, which represents about two-thirds of the
tonnage of all textiles. Innovation around polyester has been rapid because this polymer can be extruded into a variety of form factors (“formats”) that are desirable
for both manufacturers and end-users. Unfortunately, polyester is not biodegradable.
Polyester fibers, both virgin and recycled, break loose from fabrics while being worn
and during laundering. Recent studies have shown that as many as 100 million pounds
of polyester microfiber are released into watersheds each year by more than one billion washing machines currently in operation around the globe [10, 11]. The rate
synthetic plastic microfibers are released from textiles, tires, packaging, etc., continues to increase, and data suggest there may be more tonnage of non-biodegradable
plastics in the oceans than fish by 2050 [10]. Compounding these problems is the
fact that synthetics, such as polyester, absorb and concentrate toxins, such as microcystins [12]. Biologists are now documenting that many species of aquatic life that
form the base of the food chain are consuming and concentrating toxin-laden plastics
sometimes with detrimental effects [13–16]. Plastic microfiber pollution has been
discovered in seafood [17], sea salt [18], and tap water [19] samples from around
the world. Whereas microplastics in facial cleaners have been banned due to their
known deleterious effects, microplastics from synthetic textiles is a more entrenched
problem due to the scale of the textile industry [10].
Of course, there are explicable reasons why synthetic plastics have displaced market share from natural materials, such as cotton. The combination of performance
and availability are the chief reasons synthetics have taken market share from cotton. For example, whereas cotton fabrics are produced from relatively short staple
fibers, synthetics can be extruded to produce continuous filaments. Filament “format”
morphologies are advantageous both from the standpoint of production efficiency
(e.g., compatible with warp knitting) and performance (e.g., strength and durability
even when fabrics are sheer). As demand for textiles has increased in the past few
decades, synthetics produced from relatively inexpensive feedstocks have filled the
gap. Despite the increasing usage of synthetics, global demand for, and ultimate
L. M. Haverhals et al.
platform [1, 2] that has its roots in the discoveries of IL efficacy towards biopolymers—notably by Swatloski and Rogers [3], as well as Trulove, DeLong, and Mantz
[4]. NFW is peerless as it develops efficient manufacturing processes for highperformance composite materials using abundant natural materials while preserving
complex structures that are unique to natural materials [5–7]. Using tunable IL-based
chemistries, NFW is pioneering fast, scalable fabrication processes that solve systemic problems within large industries. For example, NFW has patented processes
that achieve zero-waste indigo dyeing while simultaneously recycling “waste“ cotton
fiber into denim fabrics [8]. In this chapter, we will discuss several examples of how
fabrication through welding fiber fills important manufacturing gaps and is poised to
provide renewable, biodegradable natural materials that outperform petroleum-based
plastic incumbents across many types of applications.
It is well known and documented that petroleum-based synthetics are simultaneously wonderful and terrible [9]. This is particularly obvious within the textile
industry where, during the past 60+ years, humanity has become increasingly reliant
on petroleum-based synthetic plastics [10]. Presently, the textile industry uses around
100 billion pounds of polyester annually, which represents about two-thirds of the
tonnage of all textiles. Innovation around polyester has been rapid because this polymer can be extruded into a variety of form factors (“formats”) that are desirable
for both manufacturers and end-users. Unfortunately, polyester is not biodegradable.
Polyester fibers, both virgin and recycled, break loose from fabrics while being worn
and during laundering. Recent studies have shown that as many as 100 million pounds
of polyester microfiber are released into watersheds each year by more than one billion washing machines currently in operation around the globe [10, 11]. The rate
synthetic plastic microfibers are released from textiles, tires, packaging, etc., continues to increase, and data suggest there may be more tonnage of non-biodegradable
plastics in the oceans than fish by 2050 [10]. Compounding these problems is the
fact that synthetics, such as polyester, absorb and concentrate toxins, such as microcystins [12]. Biologists are now documenting that many species of aquatic life that
form the base of the food chain are consuming and concentrating toxin-laden plastics
sometimes with detrimental effects [13–16]. Plastic microfiber pollution has been
discovered in seafood [17], sea salt [18], and tap water [19] samples from around
the world. Whereas microplastics in facial cleaners have been banned due to their
known deleterious effects, microplastics from synthetic textiles is a more entrenched
problem due to the scale of the textile industry [10].
Of course, there are explicable reasons why synthetic plastics have displaced market share from natural materials, such as cotton. The combination of performance
and availability are the chief reasons synthetics have taken market share from cotton. For example, whereas cotton fabrics are produced from relatively short staple
fibers, synthetics can be extruded to produce continuous filaments. Filament “format”
morphologies are advantageous both from the standpoint of production efficiency
(e.g., compatible with warp knitting) and performance (e.g., strength and durability
even when fabrics are sheer). As demand for textiles has increased in the past few
decades, synthetics produced from relatively inexpensive feedstocks have filled the
gap. Despite the increasing usage of synthetics, global demand for, and ultimate