Research about Functional Textiles and Yarns

PART 01 The Development History and Current Situation of Functional Textiles

1. Budding Stage

Early functional textiles were mainly used for waterproofing, fire prevention, and gas prevention needs in military and special industries.

2. Early Stage of Development

• In 1976, the US invented Gore-Tex waterproof and breathable fabric.
• Antibacterial, UV-resistant, moisture-wicking and other functions began to be used in civilian textiles.

3. Rapid Development Period

After the 1990s, intelligent and environmentally friendly textiles such as nano-silver antibacterial, intelligent response, temperature control, energy conversion, and health therapy emerged.

4. Current Trend

Functional textiles are evolving toward interdisciplinary integration and innovation—combining biology, information science, and textile engineering to create high-value products.

Definition: Functional textiles have special functions beyond warmth, coverage, and beautification—such as anti-static, wrinkle resistance, cooling, radiation resistance, heat absorption, and thermal conductivity.

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Classified by Functionality

01—Comfort & Aesthetics

• Waterproof & Oil-Repellent Textiles
  Apply spray or immersion finishing agents with special molecular structures to lower surface tension so water/oil cannot wet the fabric.

• Moisture-Absorbing & Quick-Drying Textiles
  Introduce surfactants that move sweat from skin → fabric → air, enabling rapid evaporation.

• Cool Textiles
  Modify fiber or fabric structure and apply post-processing for diffusive heat/cooling effects (used in clothing, medical, military).

02—Safety & Protection

• Flame Retardant Textiles
  2020 global market: \$1.056 B; expected \$1.315 B by 2026 (CAGR 3.73%).

• Anti-Static Textiles
  2020 global market: ¥1.14 B; expected ¥1.86 B by 2026.

• UV-Resistant Textiles
  Absorb and convert UV energy to block transmission.

03—Healthcare Textiles

• Anti-Mite Textiles
  Prevent mite-borne health risks.

• Far-Infrared Textiles
  Absorb/reflect far-infrared for insulation and health benefits.

• Antibacterial Textiles
  Antibacterial agents damage microbial cell walls. Market grew from \$11.77 B (2021) to \$12.67 B (2022), projected \$21.3 B by 2030 (CAGR 7.7%).

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PART 02 Development Trends of Functional Textiles

1. Sustainable Development
   Renewable, biodegradable fabrics showcased at 2024 International Functional Textile.

2. Diversified Development
   Multiple functions combined in one material.

3. Intelligent Development
   Embedding sensors/microelectronics for health monitoring, motion tracking, environmental response.

The main problems faced by functional textiles

• Ecological pollution
• Short functional lifespan
  Compared with functional textiles, the advantages of functional yarns are mainly reflected in the early stages of the production process and the internalization of material properties.

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Advantages of Functional Yarns over Fabrics

1. Durable Functionality
   Functions built into fiber/yarn stage—longer lasting than surface finishes.

2. Ease of Processing
   Functional components added early facilitate weaving/knitting (e-yarns, bioactive yarns).

3. Environmental Protection
   Reduces harmful chemicals; enables biodegradable or bio-based solutions.

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PART 03 The History of Functional Yarns

1. Pre/Post WWII: Protective yarns (anti-UV, anti-chemical, flame-retardant).
2. 1935–1941: Invention of polyamide & polyester—durable, modifiable.
3. 1960s: Moisture-wicking, quick-drying, warmth-retaining yarns (Coolmax®, Thinsulate™).
4. 1970s+: High-performance fibers (Kevlar, carbon fiber) for strength & heat resistance.
5. 21st Century: Nano-silver antibacterial and bio-based functional yarns (seaweed fibers).
6. Recent: Intelligent responsive yarns sensing/responding to environment & physiology.

• Example: Coated MXene cellulose-based conductive yarn (Drexel University).
• Example: Fiber-based wearable electronics (Hong Kong PolyU).

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PART 04 Current Situation & Main Categories of Functional Yarns

Functional yarns achieve special properties by adding components or changing spinning techniques:

• Antibacterial Yarn
• Flame-Retardant Yarn
• Skin-Friendly Health Yarn

a. Antibacterial Yarn

a textile with the ability to inhibit the growth and reproduction of bacteria or microorganisms.

The world’s largest producer of antibacterial textiles is located in the Asia Pacific region. China, the United States, Germany, and Japan dominate the antibacterial textile market.

According to GIR research, the global revenue of medical antibacterial yarns in 2022 reached $147.1 million, and it is expected to reach $181.7 million in 2029. The compound annual growth rate from 2023 to 2029 is 3.1%. At present, global healthcare expenditure accounts for approximately 10% of global GDP, and the proportion will continue to increase in the coming years.

Test Report of Anti-bacterial cotton

b. Intelligent Temperature-Regulating Yarn

Interacts with body temperature.

• Outlast PCM technology (US, UK)
• Intelligent diving suit (Mid6)
• Microcapsules on fabric (Triangle Company).

Mid6 company developed intelligent temperature regulating diving suit, the outer layer is closed cell neoprene foam material, and the middle interlayer is a composite of temperature sensitive hydrogel and open cell polyurethane foam material.

Triangle Company in the United States synthesized diameters of 15-40 μM microcapsules, arranged on the surface of the fabric, with temperature regulation function.

Thermoregulation display of Temsmar:

The Portuguese Center for Nanotechnology and Intelligent Materials has developed nanocapsules made from starch and containing trace amounts of waxy substances,which can be permanently attached to clothing.

37.5 dynamic technology, which embeds 37.5 particles into the yarn or fibers of clothing, can capture the infrared energy emitted by the body, remove moisture when hot, and maintain warmth when cold, is a permanent technology.

Method for producing intelligent temperature regulating fibers Hollow fiber impregnation, melt composite spinning, coating method, microcapsule spinning method.

c. Cool Yarn

processing fibers and structures, using mineral particles in fiber production to increase their Qmax; Adopting special spinning technology to increase contact area and improve coolness performance.

In 2022, the global market size of cool fabrics reached 2.4 billion US dollars. IMARC Group expects the market size to reach $3.9 billion by 2028, with a compound annual growth rate of 8.4% from 2022 to 2028.

d. Infrared Heating Yarn

an ecological heating material that absorbs infrared radiation from sunlight or the human body and converts it into thermal energy.

e. Skin-Friendly Health Yarn

Milk protein fiber is made from cow’s milk as raw material, and is processed through dehydration, degreasing, purification, and other processes to produce casein. It is combined with polyvinyl alcohol and spun by wet spinning, exhibiting silky, smooth, and healthy properties.

Good skin friendly properties, improved skin’s anti allergic ability, and delayed skin aging.

Application:

Underwear underwear, bra, baby products, winter men’s and women’s thermal underwear set.

f. High-Strength & Wear-Resistant Yarn

• Super wear-resistant and high strength (parachutes, military)
• Comfortable (high moisture regain)
• Cold-resistant to −30 °C, aging-resistant at 140 °C for 500 h.

Market (2020–2022): modified nylon demand ↑ to \$11.1 B, 2.21 M t.

g. Thermal Insulation Yarn

The thermal conductivity of gel material is as low as 0.013W/m ∙ K, the lowest density of gel is 0.16 mg/cm3, and the service life is long. It can be made into aerogel modified soft film and modified fiber.

Low thermal conductivity fibers (aerogel, graphene aerogel).

• Aerogel staple: 1.5D×38 mm; 3D×51 mm
• Aerogel filament: 50D/48F; 75D/72F; 100D/96F
• Graphene aerogel filament: 75D/72F; 100D/96F; 150D/144F

In 2022, the global aerogel market reached 5.076 billion yuan, It is estimated that by 2028, the global aerogel market size is expected to reach 8.581 billion yuan.

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PART 05 The Development Trend of Functional Yarns

1. Sustainability
   Focus on environmental protection, energy saving, and resource recycling in yarn production.

2. Fashion & Pollution Facts

   • 35% of primary microplastics in oceans come from synthetic textile washing.
   • 3,500 chemicals used in textile production; 10% harmful to humans, 5% to the environment.
   • 1 t textile produces 200 t of polluted water.
   • Fashion = ~4% of global greenhouse gas emissions.
   • Per person: 100 m³ water/year from textiles; 25% new clothes unsold; <1% recycled; 1 truck of clothes burned/landfilled every second.

3. Multifunctionality
   Integrating multiple functions into a single yarn.

   • TechNa-Poly: Antibacterial & moisture-wicking polyester
   • Hakuu-Poly: Moisture-wicking, cool feeling & anti-UV polyester

4. Intelligent Yarn
   Combines textiles with sensors/microelectronics for perception, response, communication.
   • Smart polymer market CAGR (2020–2026): 21.9%
   • Smart textiles CAGR (2020–2024): 35.0%

Conclusion

As technology and sustainability continue to shape the textile industry, functional yarns are becoming the backbone of innovation. From antibacterial protection to intelligent temperature regulation and eco-friendly performance, these yarns enable the creation of fabrics that are not only high-performance but also aligned with global sustainability goals. With increasing market demand and rapid development in smart and multifunctional textiles, functional yarns are poised to lead the future of both fashion and technical textiles. Whether you’re a designer, developer, or brand owner, exploring and integrating functional yarns is now more valuable than ever.