Sustainable Engineering of Polyethylene Fiber Materials: Advancing Functional Properties of Diverse Textile-Based Structures

Abstract

This thesis explores pathways to circularity for polyethylene-based textiles through an integrated framework that combines material experimentation, systems-level policy analysis, and cultural innovation. Focusing on olefin block copolymer (OBC) filaments—engineered with semicrystalline polyethylene hard segments and elastomeric soft blocks—the study evaluates their mechanical behavior across a range of stitch-based textile geometries. Cyclic and postfatigue tensile testing reveals how formulation and structure shape energy dissipation and durability, informing design strategies for high-performance applications such as intra-vehicular spacesuits and wearable technologies. To understand the broader systems context, the thesis analyzes barriers to integrating recycled polyethylene (rPE) into textile supply chains, identifying economic, legal, institutional, technological, firm-level, and societal constraints. It proposes targeted strategies based on global policy trends, EU case studies, and a geospatial analysis of U.S. recycling infrastructure. Finally, the work explores how generative AI can revitalize traditional craft practices—such as bobbin lace—by co-creating patterns designed for both aesthetic and functional performance in new materials. Together, these efforts propose a model for advancing sustainable textile innovation that bridges material science, circular design, and policy transformation.