Development and Evaluation of Antimicrobial Hospital Apparel Incorporating Copper Nanoparticles: Upscaling, Durability, and Hospital Assessment

Healthcare-associated infections (HAIs) remain a major challenge in clinical environments, where textiles frequently act as reservoirs for pathogenic bacteria. This study reports the development, upscaling, and hospital validation of antimicrobial hospital apparel incorporating copper nanoparticles (CuNPs) embedded within polyamide-6 core–sheath bicomponent filaments. A CuNP–polyamide masterbatch was produced through ultrasound-assisted melt extrusion and processed into continuous filament yarns under varying draw conditions. Filaments drawn at 1500 m/min exhibited uniform nanoparticle distribution, improved sheath exposure, and suitable mechanical properties for weaving. The optimized yarns were incorporated into woven narrow fabrics and integrated into prototype medical coats. Antimicrobial assays demonstrated >90% inhibition of S. aureus and 70% inhibition of P. aeruginosa. Durability testing showed minimal activity loss after 10 laundering cycles and no significant decline after up to 200 abrasion cycles. Cytotoxicity evaluation confirmed high fibroblast viability (97%), supporting the biocompatibility of the materials. In a hospital field trial, antimicrobial uniforms achieved substantial reductions in microbial burden, particularly at sleeve cuffs (30% total bacteria, 55% Gram-positive, 70% Gram-negative). It was demonstrated that intrinsically antimicrobial CuNP-embedded textiles offer a durable and safe strategy for reducing bacterial contamination in healthcare apparel and improving infection-control practices.