PolyTexx Fasteners

by Louis Parks

Abstract

This project details the development of a collection of fastening mechanisms produced from PolyTexx recycled materials. Using additive manufacturing in the form of pellet printing, fasteners are designed and printed for use on new and existing clothing garments. The aim is to create garments that can be completely recycled by the company BlockTexx without the need to disassemble existing fasteners and components. This involves reducing the material required to attach the fasteners to the garments and critical alterations that enable garments to be fully recycled. This enables BlockTexx to produce PolyTexx materials from these garments, fostering a circular economy and encouraging the recycling of both these new fasteners and the reuse of existing recycled materials.

By employing research-led and research-through-design approaches, guided primary research testing and initial design. Design-led research led a series of tests conducted to identify the material properties of PETG and PolyTexx, aimed at creating designs that leverage these materials. Additionally, testing pellet extrusion determined the ideal printing settings to create a functional and aesthetically pleasing design. Based on the findings from this testing, a selection of fasteners are created benefits from additive manufacturing’s capabilities to produce customisable and bespoke shapes, as well as compliant mechanisms.

The use of additive manufacturing and the information gathered from research and iterative testing allows for the creation of a collection of fasteners. From simple buttons to the creation of new mechanisms utilising the benefits of technology. This allows full garments containing the fasteners to be recycled in the BlockTexx S.O.F.T (Separation of fibre technology) process.

Design Intent

This study explores the creation of recyclable garment fasteners using pellet extrusion to print PolyTexx Pellets produced by BlockTexx. The chosen artefacts include a button, snap fit and zipper fastener mechanisms. The knowledge gained through secondary research helps to give a background on waste within the fashion industry and current uses of advanced manufacturing.

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BlockTexx are only able to recycle polyester and cotton blends for the soft process. Before being recycled by BlockTexx fasteners and fixtures need to be removed from garments due to the process not being able to break down the materials. Due to the output of PolyTexx material in pellet form there was an opportunity to investigate pellet extrusion which highlights the potential uses of 3D printing technologies as well as the possibilities of reuse and recycling, which were a focus throughout this study.

The purpose of this study was to explore the potential possibilities of pellet extrusion and how it can be used to print PolyTexx material. To create a selection of garment fixtures that are pellet extruded out of PolyTexx material. When attached to garments, the fixtures and the garment can be entirely recycled in the S.O.F.T process, showcasing material recycling and reuse.

Bio

Louis is a product designer who is interested in the different uses of technologies as well as the creation of new technologies and materials. His interest in this project was to investigate additive manufacturing for exploration, prototyping, and production, as well as for direct consumer use, such as pellet extrusion. He uses design skills such as physical prototyping and testing as well as digital modelling in CAD software, to develop his designs and test the limitations with the goal of innovation and exploration. He focuses on balancing function with aesthetics to create practical and aesthetically pleasing designs within the limitations of the design brief.

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