For
more than twenty years the United States has been funding the advancement
of non-woven materials for use in various military applications. Their
recent developments and the current status of research and development
programs were explained to the seminar by Steve Szczesuil, a researcher
from the Soldier RDE Center in Natick, Massachusetts. Szczesuil explained
that experimentation with non-wovens began in 1985 when the army was
attempting to improve tentage. More recent experiments include parachutes
in 1997 and gloves for use around barbed wire in 2001. The ultimate goal
is to work more non-wovens into the equipage, (or the various equipment
carried by soldiers) especially for men and women currently serving
overseas.
Szczesuil explained that woven fabrics have poor insulation, filtering and barrier properties. On top of these characteristics, woven materials carry a heftier price tag due to the extra manufacturing steps needed to produce them. It is the hope of the military to introduce non-woven materials as a means of both reducing the cost of materials as well as improving their performance. For example, it is the goal of developers to improve flame retardancy, abrasion resistance as well as resistance to chemicals. Flame retardancy, Szczesuil elaborated, is the number one priority for tentage, while improved chemical and sand abrasion is crucial for uniforms. Sand abrasion has been plaguing men and women serving in areas like the Middle East creating the need to constantly be replacing uniforms.
In order to fund and monitor research and development in non-wovens, the government has developed the Small Business Innovation Research (SBIR) grant. The SBIR is made up of three phases with failing groups being dropped as they move through them. Phase 1 gives researchers $100,000 and 9 months to prove that their concept could work. Phase 2, if achieved, puts an additional $750,000 into the hands of researchers as well as gives them 2.5 years to produce their innovation. Phase 3 facilitates the partnering up of researchers and the commercialization of the innovation for uses beyond just military. Szczesuil explicated that in order for these innovations to pay off financially they need to be accepted by the general public. As of today NanoSynTex has earned the Primary Contractor award.
The SBIR has made several accomplishments in non-wovens already. Twenty-three different styles of non-woven fabrics were developed, with this number being greatly reduced due to the high testing and standards set down. NanoSynTex has developed a new non-woven made up of three layers with a printable and water repellent outer layer and an absorbent layer on the inside, closest to the skin. These fabrics are lightweight, soft, breathable, and strong. However, their hand is still being improved upon to (a) feel better to the touch and (b) resist abrasion better. In their current state, non-wovens have reduced seven steps from the production process as well as two manufacturing sites when compared to woven materials. It is now the aim of the military to commercialize these goods for everyday consumers to reduce the costs even further. Szczesuil concluded his presentation on a hopeful note stating that while non-wovens might not be able to replace Nomex, they will greatly reduce the cost of utility fabrics.