Modeling and development of continuous textile structures utilizing 3D printing

Abstract This study explores the development of continuous textile structures utilizing Thermoplastic Polyurethane (TPU) through advanced 3D printing techniques—namely, Material Extrusion (MEX) and Conveyor Material Extrusion (CMEX). The research aims to address limitations in conventional textile manufacturing by introducing digitally fabricated textile architectures that offer design flexibility, production efficiency, and sustainability. Various TPU filaments were comparatively evaluated to determine optimal material properties, including thermal stability, tensile strength, and dyeability. Three textile geometries—plain weave, flat knit, and spacer fabric—were modeled and fabricated under optimized printing conditions. By adjusting parameters such as nozzle angle, line thickness, and inter-yarn gap, the study achieved structurally stable and visually consistent textile forms. CMEX printing, which utilizes an inclined nozzle and continuous conveyor bed, demonstrated superior capability for producing uninterrupted textile lengths, overcoming the spatial constraints of traditional MEX platforms. Surface morphology analyses and mechanical tests revealed that spacer fabrics exhibited the highest tensile and tear strengths, while flat knit structures maintained superior flexibility. Dyeing experiments confirmed that disperse dyes produced the most stable coloration, with good wash and moderate dry-cleaning fastness. This research contributes to the growing body of literature on additive manufacturing in textiles by offering practical insights into the feasibility of TPU-based printed textiles for apparel use. The findings highlight the potential of CMEX 3D printing to revolutionize textile production, enabling sustainable, on-demand, and customizable garment manufacturing.