Textiles have a very long history, but they are far from becoming outdated.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.

In recent years, several studies have investigated the flux of particulate plastic through municipal waste water treatment plants (WWTP). Challenges related to time consuming analytical methods have limited the number of sampling points and detection limits have hampered quantification of nanoplastic and microplastic fiber fluxes through WWTPs. By synthesizing nanoplastic particles and microplastic fibers labeled with a rare metal (Pd and In, respectively) which can be measured as a proxy for the plastic itself, we have circumvented major analytical pitfalls associated with (micro)plastic measurements. In this study, we spiked the labeled materials to a pilot WWTP mimicking the activated sludge process (nitrification, de-nitrification and secondary clarification). Using a mass flow model for WWTP sludge, we assessed the behavior of particulate plastic in relation to the removal of organic matter. Triplicate samples were collected from the mixed liquor and from the effluent at least twice weekly over the entire experimental run time of 40 d. Our findings show that in discrete grab samples during steady state conditions, at least 98% of particulate plastics were associated with the biosolids. A positive correlation between total suspended solids (TSS) and plastic concentrations was observed in the sludge as well as in the effluent. Because of the strong association between particulate plastic and TSS, TSS removal is likely a good indicator of plastic removal in a full scale WWTP. Therefore, additional process steps in a full-scale WWTP which further reduce the TSS load will likely retain nanoplastic particles and microplastic fibers effectively and consequently increase the removal rates.

Fiber fragments are one of the dominant types of microplastics in environmental samples, suggesting that synthetic textiles are a potential source of microplastics to the environment. Whereas the release of microplastics during washing of textiles is already well studied, much less is known about the release during abrasion processes. The abrasion of textiles may induce fibrillation of fibers and therefore result in the formation of much finer fiber fragments. The aim of this study was to investigate the influence of abrasion of synthetic textiles on the formation of microplastic fibers and fibrils. Fleece and interlock textile swatches made of polyester were abraded using abrasion tests with a Martindale tester. The microplastic fibers and fibrils formed during abrasion were extracted from the textiles and characterized in terms of number, length, and diameter. The microplastic fibers demonstrated the same diameter than the fibers found in the textiles (fleece: 12.3 μm; interlock: 12.7 μm), while fibrils with a much smaller diameter (fleece: 2.4 μm; interlock: 4.9 μm) were also found. The number of fibrils formed during abrasion in both textiles was higher than the number of microplastic fibers. The majority of the extracted microplastic fibers had a length between 200 and 800 μm, while most fibrils were between 30 and 150 μm, forming two distinct fiber fragment morphologies. The number of microplastic fibers formed during abrasion was 5 to 30 times higher than the number of microplastic fibers that could be extracted from non-abraded samples. The number of fibrils increased after abrasion by more than a factor of 200 for both fabric types. The fibrils formed during abrasion have diameters that fall within the inhalable size for airborne particles. The potential release of fibrils into air during wear of textiles thus raises questions about the human exposure to these materials. Since the Martindale tester can simulate a daily application scenario of textiles over a prolonged period only in a limited way, future studies are needed to establish the correlation between the test results with a real-world scenario.