Blended Armor: From Monofiber To Multifiber

Blended fibers can raise protection levels and also increase end-user confidence in multi-hazard protective applications.

By Eve Lamb

As workplace risks evolve, with potential injuries from sharp metal edges and abrasive surfaces to thermal hazards, traditional, single-fiber protective fabrics often fall short. Enter hybridization: the strategic blending of high-performance fibers like high-performance polyethylene (HPPE), tungsten, steel, glass and basalt. These hybrid constructions are now reshaping personal protection boundaries, delivering multi-hazard resistance while maintaining wearer comfort and mobility.

From Monofiber To Multifiber: A Structural Shift

For decades, personal protective equipment (PPE) relied on monofiber solutions: aramids for heat, HPPE for cut or steel for slash protection. Yet each fiber has limitations: HPPE degrades above 80°C1, and steel adds considerable weight. Today, performance demands are shifting toward multi-fiber blends, engineered to meet the stringent requirements of EN 388:2016 and ANSI/ISEA 105-20162,3.

By combining fiber characteristics — tensile strength, rigidity, elasticity and thermal tolerance —engineers are tailoring protection profiles that meet or exceed the most demanding classifications.

HPPE: The Lightweight Backbone

HPPE remains the cornerstone of most cut-resistant fabrics because of its exceptional strength-to-weight ratio, which is up to 15 times stronger than steel by weight4. It provides core flexibility and breathability while anchoring the structure of hybrid yarns. Blends incorporating HPPE with glass, steel or tungsten leverage shock-absorbing capabilities, allowing stiffer fibers to act as deflection barriers. This synergy delivers superior protection without bulk.

Glass & Basalt: Sharp Defense, Thermal Edge

Glass fiber contributes high rigidity and puncture resistance, but its brittleness can hinder comfort. Basalt, a naturally derived volcanic fiber, is gaining traction as a heat- and chemically resistant alternative. Withstanding temperatures up to 982°C and offering smoother yarn handling, basalt is now a compelling substitute for glass or aramid blends5,6. Basalt’s lower flammability and improved chemical durability make it ideal for applications involving heat, corrosion or frequent abrasion.

Metal Yarns: When Strength Demands Edge

Metallic filaments, primarily stainless steel, have long enhanced cut-resistant gloves and garments. With a Mohs hardness of 7.5 and a melting point of 3,422°C, tungsten microfilaments deliver extreme slash and puncture resistance in lightweight configurations7. When integrated into knitted HPPE or basalt blends, these metals help garments reach EN 388 Cut Level F and ANSI A7–A9, with minimal ergonomic compromise.

Applications Beyond Gloves

While gloves remain the most visible application, hybrid protective fabrics are expanding into new fields, including:

  • Riot control and public order suits — offering slash and puncture protection;
  • Protective uniforms for correctional and detention facility staff;
  • Every day, urban security apparel— discreet, slash-resistant garments for private security;
  • Bite-resistant garments for mental health and special education professionals;
  • Seclusion wear and protective clothing for high-risk patients;
  • Cut-resistant workwear for steel, glass and metal fabrication industries;
  • Abrasion-resistant sleeves and aprons for meat processing, butchery and food production;
  • Multi-threat garments for recycling and waste management workers handling sharp or abrasive materials;
  • Protective wear for automotive assembly and maintenance involving sharp components;
  • Slash- and cut-resistant sports apparel such as hockey socks, skating, skiing and fencing base layers;
  • Motorcycle base layers with integrated cut and impact abrasion protection;
  • Footwear reinforcements for extreme sports including climbing, trail running, skating and snow-boarding;
  • Protective underlayers for equestrian and contact sports;
  • Lightweight slash- and stab-resistant garments for civilian use in high-risk areas;
  • Travel wear and backpacks with integrated cut protection for anti-theft protection;
  • Tactical apparel for military or special operations; and
  • High-resistance gear for search and rescue or firefighting when paired with heat-resistant fibers.

This growth reflects a shift toward wearable, ergonomic protection across industries where safety, movement, and aesthetics must coexist8, but also a sustainable angle, as garments and apparel will have an extended lifespan.

Hybrid protective fabrics are expanding into new applications including back-packs with theft protection, motorcycle base layers and riot control gear.

Yarn & Fabric Engineering: Protection By Design

The behavior of blended fabrics is influenced not just by fiber selection but also by yarn construction — core-spun, wrapped or twisted — knit architecture — flat, warp or 3D — and surface treatments. For instance, a glass and HPPE core-spun yarn in a flat-knit structure feels soft and elastic until it meets a blade. The moment stress is applied, the rigid inner fibers engage delivering what is known as “engineered resistance”9. This con-trolled activation enables garments to remain wearable without compromising safety. The future of protective textiles lies in engineered blends that merge strength, flexibility, thermal control and comfort. By harnessing the complementary properties of HPPE, steel, tungsten, glass, and basalt, fabric developers are no longer forced to choose between durability and wearability, instead achieving both. As industries demand more agile, multi-threat protection, blended fiber technologies are poised to become the new standard, raising not just protection levels, but also end-user confidence.

The Circularity Challenge

Hybrid fabrics pose significant recycling challenges due to mixed fiber content. A fully circular model is still much needed, and sustainability is becoming a driving force in the research and development of advanced PPE. Ultimately, the goal is to move from a linear model, where protective garments are made, used and discarded, to a circular economy where materials are recovered, repurposed or regenerated with minimal waste. This will likely mean a shift from “forever” blends to thoughtful hybridization for technical textiles, balancing safety and sustain-ability without sacrificing performance. Blended protective fabrics are the future of protection, but without a circular focus, they risk becoming tomorrow’s ecological problem. As the industry embraces innovation in material science and sustainable design, the next generation of PPE should protect the wearer and respect the planet.


References
1 DSM Protective Materials – HPPE Performance Characteristics
2 EN 388:2016 Standard for Protective Gloves Against Mechanical Risks
3 ANSI/ISEA 105-2016 Cut Resistance Classification
4 High-Performance Fibres: Fundamentals and Applications, Woodhead Publishing
5 BFC Research Group – Basalt Industry Analysis, 2023
6Mechanical and Thermal Performance of Basalt-Fibre-Reinforced Composites, Elsevier, 2022
7 Refractory Metals Handbook – Properties of Tungsten and Its Alloys
8 EU-OSHA Guidelines on PPE and Worker Comfort
9 Textile Research Journal, 2021 – “Advanced Yarn Structures for Technical Textiles”


Editor’s Note: Eve Lamb is a technical textile consultant with more than a decade of experience in protective fabric innovation, specializing in cut, abrasion, tear and puncture-resistant materials. She has supported strategic product launches and brand content development across PPE, defense, industrial, and sportswear sectors.


2025 Quarterly Issue III

Transformers Foundation Launches Water Benchmark For Indigo Dyeing

Transformers Foundation, with support from Naveena Denim Ltd. and the Indigo Council, has released “A Reference for Water Consumption During Indigo Dyeing,”the first cross-industry benchmark for water usage in rope and slasher dyeing systems. The study is based on data from seven mills in Pakistan, Türkiye, Italy and China, and highlights how process control and monitoring can reduce water use in post-dye washing and rinsing.
The initiative arrives as regulators in the European Union, United Kingdom, and United States push for transparency in sustainability claims. Andrew Olah, Transformers founder, said: “Without transparency and specificity, such figures become marketing jargon: just enough to sound responsible, never enough to be meaningful. Real sustainability requires real data, and this report provides exactly that.”

“This report marks a historic first in the denim industry — bringing together mills from across the globe to share verified, third-party data on actual water use,” said Paolo Leidi, Transformers’ Technical director.

“Our goal was not to rank mills, but to equip brands, designers, and retailers with meaningful benchmarks, enabling them to assess how seriously a mill is addressing water reduction.”

2025 Quarterly Issue III

Tonello Delivers 10,000th Machine To Pacific Jeans

Italy-based Tonello recently marked a milestone with the delivery of its 10,000th machine to Bangladesh-based Pacific Jeans, symbolizing more than production— it’s decades of collaboration dating back to the early 1990s. Pacific Jeans’ founder, M. Nasir Uddin, was the first in Asia to adopt Tonello’s G1 360, helping establish advanced garment technology in Bangladesh. Today, the partnership continues through the next generation of both families, emphasizing innovation, responsibility, and shared values.

The 10,000th machine “… reflects decades of collaboration, during which we’ve grown and learned together, always driven by a common curiosity to anticipate trends and embrace new challenges,”said Alice Tonello, R&D and marketing director.

2025 Quarterly Issue III

LAIP Introduces MINI JET

LAIP’s new MINI JET sample dyeing machine can dye up to 20 meters per color.

Italy-based dyeing machine manufacturer LAIP has introduced the MINI JET. Designed for in-house sampling, Mini Jet enables textile producers to move beyond traditional lab dips that test only a small quantity of fabric by direct dyeing of up to 20 meters per color. This allows real garment prototypes to be created, providing insight into both color accuracy and fabric performance under production conditions.

According to LAIP, the machine ensures 100-percent dye reproducibility, with results transferable directly to industrial dyeing machines without recalibration. Mini Jet also offers shorter dyeing cycles, supporting more sample runs per day and faster development cycles. Industry 4.0 ready, it integrates with digital systems for remote monitoring, analytics, and process traceability.

2025 Quarterly Issue III

TEXTILCOLOR Acquires Schoeller Technologies

TEXTILCOLOR AG, Switzerland, has acquired Schoeller Technologies AG from Switzerland-based Schoeller Textil AG, expanding its international presence and creating new capacity for textile and chemical solutions. Schoeller Technologies, known for licensing and marketing functional and protective textile innovations, will now be integrated into Textilcolor’s new “Brand Management”unit. Existing partnerships and technology marketing will continue under the Textilcolor identity. Hans Kohn, former Schoeller Technologies COO will lead the new Brand Management division.

“The acquisition is a consistent milestone in our long-term growth strategy,”said Detlef Fischer, CEO, Textilcolor.“With Schoeller Technologies, we are not only gaining renowned technologies, but also a highly qualified team with unique expertise. We will continue to develop and refine the products manufactured to date in this partnership in order to continue to provide our customers with future-oriented and sustainable technologies.”

2025 Quarterly Issue III

Sparxell, Positive Materials Launch Bioinspired Ink

Sparxell has launched a plant-based textile ink, which is available in matte and shimmer finishes.

England-based color technology company Sparxell has partnered with Positive Materials to launch a plant-based, biodegradable structural color ink for textiles. According to the company, the ink uses engineered cellulose to create vibrant hues without toxic dyes, mined minerals or petroleum-based ingredients. The debut, available in a signature blue with matte and shimmer finishes, allows brands to integrate the technology through standard orders.

Dr. Benjamin Droguet, co-founder and CEO of Sparxell, said: “This textile ink launch transforms how brands can access our breakthrough technology. For too long, the textile industry had no choice other than to accept that vibrant colors meant environmental damage. Sparxell’s bioinspired technology shatters that assumption, delivering exceptional results from plant-based cellulose.”

The ink is now available through Positive Materials, with printed cotton jersey products featuring the ink set to enter European markets in September 2025.

2025 Quarterly Issue III

Archroma Launches Washing-Off Auxiliary

The right side of the garment was treated with CYCLANON XC W e, while the left side was treated with other soaping agents.

Switzerland-based Archroma has introduced CYCLANON® XC-W e, a washing-off auxiliary designed to improve color fastness and efficiency in cellulosic dyeing under high-electrolyte or hard water conditions. Conventional agents often fail to fully remove unfixed dye, leading to extra rinsing, uneven shades and potential quality rejections.The product enables shorter washing cycles, reducing water, energy, and chemical use while increasing throughput. Cyclanon XC-W e is part of Archroma’s SUPER SYSTEMS+ port-folio and meets current MRSL and RSL compliance standards.

“With Cyclanon XC-W e, we are building on our proven trio-polymer platform to give mills a way to meet rising brand expectations for durable, high-quality casual wear with a lower environmental footprint — all at a cost profile comparable to conventional washing-off agents,” said Dhirendra Gautam, vice president, Global Marketing and Strategy, Archroma.

Archroma also recently introduced a full redesigned website, located at achroma.com, aimed at improving the user experience while also encouraging sustainable choices.

Livinguard Introduces Two-In-One Better Fresh

Switzerland-based Livinguard Technologies has introduced Better Fresh, a textile treatment that combines odor control with reduced microfiber shedding. The solution can cut fiber fragmentation by up to 80 percent, extending product life and lowering environmental impact.

Validated through internal and independent tests, the technology binds permanently to fibers, limiting chemical leaching and microplastic release while fitting into existing production processes. By merging odor control with fiber protection, brands can offset costs by replacing current odor-control finishes.

“No solution is perfect — neither is this one,”said Dr. Alok Goel, Research and Development manager at Livinguard Technologies AG.“But this technology provides meaningful impact and it can be implemented today to complement ongoing efforts to mitigate microfiber shedding that are already ongoing. As a society we must act today and stop the bleeding.”

2025 Quarterly Issue III

Cupron® Launches Cupron Clear™

Cupron Performance Additives, Richmond,Va., has launched Cupron Clear™, a transparent and stable liquid form of copper designed for microbial control across polymers, liquids and coatings. According to the company, the platform offers a safer and more sustainable alternative to traditional additives like QUATs and isothiazolinones, many of which face regulatory scrutiny. Cupron Clear can be applied in industries including personal care, hygiene, construction, textiles, plastics, paints, adhesives and sealants. Discussions with global partners are underway to bring the product to market.

“This new liquid copper platform addresses the frustrations for so many different industries and dramatically expands the applications that can enjoy the benefits of Cupron innovations,” said Cupron CEO Chris Andrews.“It’s the direct result of focused R&D and our belief that economic, safer, sustainable technologies should replace legacy materials that no longer meet regulatory or performance standards.”

2025 Quarterly Issue III

Understanding And Mastering Odor Control In Textiles: A Scientific Approach

Figure 1

An effective odor control solution for textile products needs to address the multifaceted sources of odor.

By Ryan Scott

Human body odor, while often invisible, poses a significant and persistent challenge in the world of textiles. It’s more than just an unpleasant smell; it represents a key consumer pain point that can dramatically impact brand perception and product longevity. As interest in performance textiles and sustainable practices grows, so does the demand for truly effective and lasting odor control. Yet, achieving this goal is far from simple. It requires a deep scientific understanding of human body odor as a multifaceted phenomenon, moving well beyond simplistic assumptions and single-solution approaches. As the textile industry continues to innovate, mastering odor control hinges on embracing the chemistry at play and adopting comprehensive, scientifically rigorous evaluation methods.

A Complex Chemical Symphony

Contrary to common belief, human body odor cannot be attributed to a single source or compound. Instead, it is a complex and dynamic mixture of volatile organic compounds (VOCs). This intricate chemical symphony is influenced by a confluence of factors, including an individual’s biology, their environment, the specific chemistry of the textile substrate and the activity of skin-resident microbes. The AATCC 2017 White Paper on Odor Evaluation Techniques for Textiles highlighted this complexity, presenting real-world case studies where detailed odor intensity and character profiling consistently revealed that garments carry a broad array of olfactory signatures. Trained sensory assessors in these studies identified a diverse range of descriptors, including animalic, earthy, floral and chemical notes, confirming that body odor originates from multiple families of odorants, not just a single compound.

Among the most common and impactful odorants found in textiles are distinct chemical entities, each presenting unique challenges for odor control technologies:

  • Isovaleric Acid (C5H10O2): This short-chain branched fatty acid is characterized by a pungent, cheesy odor. It is primarily produced through the microbial metabolism of amino acids, such as leucine. Being moderately hydrophobic, isovaleric acid tends to bind readily to synthetic fibers, making its removal a persistent challenge.
  • Acetic Acid (CH3COOH): A small, polar carboxylic acid, acetic acid is often a byproduct of sweat fermentation. Its sharp, vinegar-like smell is distinct from isovaleric acid. Due to its higher solubility in water and volatility, it behaves differently in textile substrates, requiring different neutralization strategies.
  • Ammonia (NH3): This basic, highly volatile gas is formed through the degradation of urea, a component of sweat. Known for its sharp, irritating smell, ammonia can rapidly escape fabrics. However, its alkaline nature presents a different set of challenges for odor neutralization technologies compared to acidic compounds.
  • Nonenal (C9H16O): An unsaturated aldehyde, nonenal is frequently associated with the “cardboard” or “greasy” odor often linked to aging body odor. This molecule is highly lipophilic, meaning it strongly binds to fibers, particularly polyester, and is notoriously difficult to remove, demanding specific and robust strategies for effective neutralization.

The critical takeaway here is that each of these molecules represents a distinct chemical class — acid, base, aldehyde — and interacts uniquely within textile matrices. An odor control solution designed to capture or neutralize an acid may not effectively interact with a base like ammonia or a nonpolar aldehyde such as nonenal. Therefore, a truly effective solution must possess a multifaceted mechanism capable of addressing this broad chemical diversity.

Figure 2

Why Single-Odorant Testing Methods Fall Short

Despite the inherent chemical diversity of human body odor, a prevailing practice in the textile industry has been to validate many odor control technologies using only a single odorant, most commonly isovaleric acid. While isovaleric acid serves as a useful benchmark for certain aspects of foot and sweat odor, relying solely on it for performance validation is fundamentally insufficient to represent the full complexity of body malodor. This narrow testing can lead to misleading claims, as products appearing effective against isovaleric acid may utterly fail to address other critical odorants like nonenal or ammonia, which significantly impact perceived freshness, particularly in active wear or among aging populations.

Furthermore, the choice of fabric composition plays a critical, yet often underestimated, role in odor performance and can exacerbate the limitations of single-odorant testing. Spandex, or elastane, is a prevalent fiber used in performance apparel due to its stretch and recovery properties. However, its inclusion significantly alters odor behavior. Spandex is known to have a greater affinity for isovaleric acid, nonenal, and acetic acid than common synthetics like polyester or nylon. This affinity allows spandex to delay the release of odorants, which can inadvertently inflate odor reduction results in controlled laboratory settings. Crucially, this retention does not equate to true odor elimination; in real-life wear, trapped odors in spandex may be rereleased over time, especially when exposed to body heat and motion. Consequently, testing with spandex-containing fabrics, particularly when combined with isovaleric acid-only evaluation, risks overstating a product’s true performance and masking the technology’s limitations in broader, real-world scenarios.

To genuinely understand and enhance textile odor control, the industry must evolve beyond these simplistic test models. A multi-odorant, chemically diverse evaluation approach is imperative to reflect the true nature of human malodor.

Establishing The Gold Standard: ISO 17299

Recognizing the limitations of single-odorant testing and the complex nature of body odor, the global textile industry has increasingly turned to the ISO 17299 standard as the benchmark for assessing deodorant properties in textiles. This international standard is specifically designed for comprehensive, multi-odorant and chemically diverse evaluation, ensuring a more accurate representation of real-world performance.

The ISO 17299 standard is com-posed of several parts, each addressing specific aspects of odor assessment:

  • ISO 17299-1: General Principle — This foundational part outlines the overarching methodology and principles for evaluating deodorant properties, emphasizing a holistic approach to address diverse odorants.
  • ISO 17299-2: Detector Tube Method — This section details the procedure for evaluating deodorant performance using detector tubes, primarily for assessing gaseous odorants such as ammonia and acetic acid.
  • ISO 17299-3: Gas Chromatography Method — This part specifies the use of gas chromatography for the precise quantification of odor reduction for more complex VOCs like isovaleric acid and nonenal. This instrumental analysis provides objective and repeatable data on a technology’s efficacy against these key odorants.

To achieve ISO 17299 certification, textile products must meet minimum reduction rates for each of the four identified key odorants — isovaleric acid, nonenal, acetic acid, and ammonia (See Figure 3). These thresholds were rigorously established based on extensive sensory testing and validated through the instrumental analysis methods outlined in the standard, ensuring that the defined reduction levels correspond to a noticeable and effective improvement in perceived freshness.

This rigorous, multi-faceted standard serves as the critical baseline for any credible odor control claim, pushing the industry towards more robust and reliable solutions that truly address the spectrum of human body odor.

Next-Generation Odor Control Technologies

The growing understanding of odor complexity, coupled with the rising consumer demand for high-performing and sustainable textiles, has spurred innovation in odor control technologies. Many traditional solutions, particularly those relying on metal-based chemistries or biocides, or those with limited wash durability, have proven inadequate in meeting these evolving demands, especially after repeated home laundering. This landscape has driven the development of advanced solutions that are designed to effectively man-age the full spectrum of malodors while aligning with modern safety and environmental standards.

A compelling example of this next-generation approach is Freshology™, developed by Microban International Ltd., Huntersville, N.C. This technology represents a nature-inspired, heavy-metal-free and non-biocidal solution specifically engineered to neutralize the broad spectrum of impactful body malodors, including isovaleric acid, acetic acid, ammonia and nonenal.

Unique Mechanism

The science behind Freshology centers on its unique mechanism of action, which involves a proprietary blend of polymers and natural components (See Figure 4). This blend is designed to capture and neutralize VOCs through a combination of physical and chemical interactions. The captured odorants are then later released and effectively washed away during laundering. This cyclical mechanism is key to the technology’s ability to maintain lasting freshness across repeated uses and launderings, making it a robust option for performance textiles.

Figure 4

In terms of application, technologies like Freshology are often designed for seamless integration into existing textile production lines. For instance, it can be applied through standard pad finishing processes without requiring additional steps, and it typically demonstrates compatibility with common fiber types such as polyester, nylon, and various blends, as well as a flexible pH range and curing temperatures.

In practice, a technology built on these principles has undergone rigorous testing against all four primary odorants identified in the ISO 17299 standard. Such technologies are observed to consistently meet or exceed the standard’s reduction thresholds across a wide range of fabric types, including synthetics that typically present a challenge for odor management. Furthermore, their performance is designed to exhibit observed durability and retain effectiveness even after numerous home launderings, indicating their potential for providing long-term odor control in demanding textile applications.

Beyond performance, sustainability and safety are increasingly vital considerations. Advanced odor control technologies often feature environmental profiles that are heavy metal-free and non-biocidal, aligning with evolving regulatory landscapes and consumer preferences. Such innovations may also pursue relevant textile certifications like Oeko-Tex® Eco Passport and Bluesign® Approval, signaling adherence to high standards for environmental health and safety. The development and patenting of unique odor capture systems under-scores the commitment to scientific advancement within this field.
Elevating Textile Freshness With Scientific Rigor

The complexities of human body odor demand a sophisticated, multi-odorant approach to effective odor control in textiles. Single-odorant testing methods are insufficient to capture the full picture, potentially leading to products that underperform in real-world conditions. The ISO 17299 standard serves as a critical global benchmark, offering a comprehensive and scientifically rigorous framework for evaluating a technology’s ability to neutralize the diverse chemical spectrum of body malodor.

Innovative, science-backed solutions, such as Freshology, are crucial for brands aiming to deliver on the promise of long-lasting freshness and superior performance. By embracing a deep scientific under-standing of odor chemistry and adopting thorough testing methodologies, the textile industry can advance beyond mere masking agents to create textiles that truly neutralize odors across the full spectrum, ensuring they remain fresher longer and meet the increasingly high expectations of today’s discerning consumers.


Editor’s Note: Ryan Scott is a senior product development chemist at Microban International Ltd., Huntersville, N.C.


2025 Quarterly Issue III

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