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Massachusetts Institute of Technology

Innovations in Textile Engineering: Fibers, Yarns, Nonwovens, & More

Massachusetts Institute of Technology via edX

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Overview

What makes fiber a unique engineered-to-the-extreme state of soft matter?

This online course from the MIT Department of Mechanical Engineering introduces the key principles used to engineer and manufacture fibers and textiles. You will learn the fundamentals of polymer science, mechanical, thermal, and moisture transport engineering of fibrous media. You’ll get an overview of industrial and lab-scale textile manufacturing techniques and machinery, visual color science and engineering, and design of composite fibrous materials.

You will learn how to hierarchically design new materials and products that derive their cumulative properties from the fiber as the smallest engineering building block. You will also get a feeling for what it means to innovate in the industry that literally touches every single person on the planet at any given moment of time, amplifying the impact of any innovation compatible with its large-scale distributed industrial and supply infrastructure.

The course will guide you through several real-world examples of iconic commercialized textile-based technologies. The course will reinforce the learning process via peer-to-peer discussions, and will culminate with the practical exercise of crafting your own mock patent applications. Several mock applications created by MIT students taking the residential version of this class have been converted into filed utility patent applications.

Syllabus

Week 1
Introduction, course overview, and a concept map. Basic characteristics of fibers and yarns. Textile terminology and units. Natural fibers: plant-, animal-, and mineral-based. Yarn spinning from staple fibers. Spinning preparation: carding, combing, drawing & roving. Ring, open-end rotor and air-jet yarn spinning.

Week 2
Innovation in textile industry & intellectual property protection. Utility patent structure & coverage. Design patent structure & coverage. An anatomy of a patent application. Patent infringement and invalidation. Richard Arkwright’s spinning frame patent of 1769 v. his carding technology patent, 1775.

Week 3
Bio-derived man-made fibers. Intro to wet, dry, and melt spinning techniques. Cellulose-based rayon fibers. Alternative solvents for cellulose; cupro & lyocell processes; Tenacity as a measure of fiber strength. Dry spinning. Regenerated protein fibers. Polymer cross-linking. Engineering v. specific stress, unit conversion.

Week 4
Synthetic fibers and textiles production. Nylon history; condensation polymerization. Fiber-making polymers. Polyethylene; addition polymerization. Degree of polymerization and molecular weight. Polyester. Fiber melt-spinning and spin-doping. Fiber drawing; strain-induced crystallization; natural draw ratio. Yarn classification by orientation & crystallinity (FOY, POY, etc.)

Week 5
Mechanical characterization. Stress-strain curve. Young’s modulus. Standard tensile tests. Structural characterization: X-ray scattering; Scanning electron microscopy (SEM); Crystallinity analysis via wide-angle X-ray scattering (WAXS). Herman’s orientation function; birefringence. Raman scattering. Vibrational modes of polymer molecules. Curve fitting and peak deconvolution. Thermal properties of fibers. Differential Scanning Calorimetry (DSC). Glass transition, melting, crystallization, cold crystallization; decomposition. Testing standards. Melt flow index.

Week 6
Yarn engineering. Smooth and textured yarns. Specialty yarn engineering. Hollow spindle fancy-yarn machines. Elastic fibers. Cyclic yarn testing. Auxetic fibers & yarns. Fiber properties engineering and characterization. Contact angle and fiber wettability. Fiber surface treatment & coating. Human color vision. Chemistry of natural and synthetic dyes. Pigment-based and structural color, spin(solution)-dyeing. Engineering thermal and electrical conductivity of fibers. Engineering reversible thermal energy storage in fibers.

Week 7
Weaving. Warp & weft yarns. Basic functions and elements of looms. Loom primary & secondary motions. Weaving preparation: yarn sizing & loom warping. Shedding mechanisms: cam, dobby, Jacquard. Picking mechanisms: shuttle, projectile, rapier, airjet, waterjet. Edmund Cartwright’s power loom. Crompton fancy power loom. Recent innovations in loom technology. Weaving patterns & notations. Plain, twill, satin, rib, and matt weaves. The role of yarn twist and texture. Mechanical properties of woven fabrics. Tensile testing standards for textiles: grab v. strip test. Textile area density & thread count. Crimp engineering & characterization. Knitting. Lee’s stocking frame. Bearded v. latch needle, stitch formation process. Weft-knitted fabrics. Course & wale. Circular knitting machine operation principle. Knitted loop notations; plain (jersey), flow (float, missed) & tuck stitches. Rib & purl knits. Yarn plating. Fleecy, terry/plush & pile fabrics. Spacer fabrics. Whole garment knitting. Warp knitting.

Week 8
Project 1: a dissection of an iconic textile product/technology.

Week 9
Nonwovens. Felting. Web formation & bonding. Drylaying by carding. Airlaying. Wetlaying. Direct/polymer/spunlaid nonwovens. Binder types & curing processes. Meltblown fabric formation. Electrospinning. Mechanical bonding: Needle-punching, Hydroentangling, Stitch-bonding, Ultrasonic welding. Fiber-reinforced composites & laminates. Matrix & dispersed phase of a composite. Stiffness and strength of fiber-reinforced composites, rule of mixtures. Monomaterial textile concept. 3D printing on textiles. Moisture-repellent and moisture-absorbing textiles. Push-pull hierarchical textiles. Industrial standards for textile testing for moisture transport. Engineering color & light reflectance on the textile level. Heat transport engineering. Insulating, heat-reflective & cooling textiles. Standards for textile testing for heat transport.

Week 10
Electronic(+) textile envelope engineering. Fiber- & textile-integrated sensors, capacitors and actuators. Optical fiber engineering, manufacture, and integration. Shape memory polymers. Artificial muscles. Mechanocaloric fibers. Fabrication, knitting & weaving of specialty fibers. Embroidery. Melt-spinning from preforms.

Week 11
Textiles and the environment. Lifecycle analysis of fibers, textiles and garments. Higg’s index. Mechanical v. chemical recycling and automated sorting. Supply chains.

Week 12
Project 2: mock patent application drafting.

Taught by

Svetlana Boriskina and Ikra Shuvo

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