3D printing on pre-stressed textiles: peel test evaluation of adhesion factors in 4D textiles

Purpose 4D textiles are created through 3D printing on pre-stressed textiles. The flexible textiles generate tension during the printing process, while the 3D-printed structure acts as a reinforcement, storing this tension within the material. These components undergo state transitions in response to external stimuli. In such cases, it is essential to ensure that the printed elements remain reliably bonded to the textile substrate and do not delaminate. Therefore, the interface between the 3D-printed structure and the textile property plays a crucial role. In order to solve this potential problem and reduce material and time consumption in the experimental phase, a systematic investigation of adhesion performance is necessary. Design/methodology/approach This study systematically examines the key parameters influencing adhesion at this interface, including textile type, printing parameters, printed materials and pre-tensioning. A comprehensive 2ˆn factorial experimental design was employed to analyse the interactions between these parameters. Adhesion strength was evaluated using 180° peel tests. Mathematical evaluation methods, including Analysis of Variance (ANOVA), effect calculation and confidence interval analysis, are applied to systematically assess the influence of each factor. The evaluation is performed using an organized results table, which simplifies the analysis process and facilitates the interpretation of significant effects and interactions. Findings In this study, nine factors influencing interfacial adhesion in 4D textiles were analysed using a 2ˆn factorial design. Key findings show that nozzle distance critically affects adhesion, with 0.05 mm being optimal. Higher textile pre-tension reduced adhesion, while lower pre-tension enabled 4D shape transformation. Nozzle temperature significantly influenced adhesion, with 220 °C optimal for PLA. Textile structure was also critical: dual tricot fabrics with elastane improved mechanical interlocking. The interaction between pre-tension and textile type also affects adhesion. Material choice affected adhesion, with silicone rubber achieving the highest values. In contrast, mesh orientation, printing speed and bed temperature showed no significant effects within the tested ranges. Originality/value The findings of this study provide a systematic analysis of interfacial adhesion, supporting the efficient production of 4D textiles and 3D-printed structures on textile substrates. By applying the identified key parameters, strong adhesion can be achieved without repeated trial-and-error testing, ensuring structural integrity for repeated state transformations in 4D textiles. Additionally, improved process reliability contributes to more sustainable manufacturing by reducing material waste and the need for auxiliary bonding agents. These insights enhance the robustness and scalability of 4D-textile production and open new application possibilities in wearable electronics, soft robotics and adaptive architectural structures.