motivation

In the billion-dollar fiber market, fossil-based polyesters (PES) dominate the clothing sector with a 52 % share. Unfortunately, PET, the most commonly used PES, cannot be produced 100% bio-based on an industrial scale, unlike polyethylene (PE). Bio-based PE (bioPE), a drop-in polymer derived from fermented starches or sugars, matches the properties of fossil-based PE and is easily recyclable. It is also cheaper than other biopolymers used in fibers and can be processed at lower temperatures, saving energy. Spun-dyed bioPE offers significant environmental benefits: it uses 50 % less energy and water than conventional dyeing processes and emits 60 % less CO₂. Life Cycle Assessments (LCA) predict that PE could substantially reduce the textile industry’s ecological footprint, with spun-dyed bioPE amplifying this reduction. Additionally, PE textiles are IR-transparent, providing passive body cooling. Despite these advantages, PE is not yet used in clothing. Preliminary research at ITA indicates that PE can be processed into spun-dyed filaments and knitted swatches with a promising texture.