Textiles have a very long history, but they are far from becoming outdated. They gain new importance in technical applications, and man-made fibers are at the center of this ongoing innovation. The development of high-tech textiles relies on enhancements of fiber raw materials and processing techniques. Today, melt spinning of polymers is the most commonly used method for manufacturing commercial fibers, due to the simplicity of the production line, high spinning velocities, low production cost and environmental friendliness. Topics covered in this review are established and novel polymers, additives and processes used in melt spinning. In addition, fundamental questions regarding fiber morphologies, structure-property relationships, as well as flow and draw instabilities are addressed. Multicomponent melt-spinning, where several functionalities can be combined in one fiber, is also discussed. Finally, textile applications and melt-spun fiber specialties are presented, which emphasize how ongoing research efforts keep the high value of fibers and textiles alive.

High-speed melt spinning of racemate polylactide (r-PLA), which is a blend of equal amounts of poly(l-lactide) and poly(d-lactide) molecules, was performed up to the take-up velocity of 7.5 km/min. In the fiber structure analysis, particular attention was paid to the formation of stereocomplex crystals, because this crystal form has a melting temperature about 60° higher than the homocrystals. It was found that highly oriented and highly crystallized fibers containing the α-form and stereocomplex crystals were obtained when the take-up velocity exceeded about 4 km/min. The amount of stereocomplex crystal was higher under the spinning conditions of higher take-up velocity, lower throughput rate, and lower extrusion temperature. Under these conditions, higher tensile stress can be applied to the spinning line, and therefore, the orientation-induced crystallization is promoted. Annealing of the fibers obtained at high-take-up velocities, such as 6 km/min, which already have the crystalline structure with a c...