Post on 10-Apr-2018
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The Future is FIBRESVision and Strategy
Creating a Vibrant Fibre Sector in the Future Australian Economy
http://en.wikipedia.org/wiki/Image:CSIRO.png8/8/2019 Future is Fibres Strategy
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CONTRI BUTI NG AUTHORS
Nigel Johnson Chief, CSIRO Textile and Fibre Technology
Keith Cowlishaw Head of School, Textiles & Fashion, RMIT
Xungai Wang Alfred Deakin Professor, Centre for Material and
Fibre Innovation Deakin University
Peter Kreitals Manager, Australian TCF Technology Network
Lachlan Caddy Network Officer, Australian TCF Technology
Network
ACKNOW LEDGEMENT
The authors would like to thank all the various parties that have contributed to thedevelopment of this paper, particularly the participants at the TCF Technology Networks2007 Strategy Workshop on 23 August and most notably the collective members of theNetworks Advisory Committee and Strategy Group, all of whom have generouslycontributed their thoughts, efforts and time:
Paul Cacioli, Gale Pacific
Sam Cassarino, Yakka
Robert Bell, Madison Filter
Steve McMillan, Melba Industries
Darren OLoghlin, Bruck Textiles
Thomas Seeger, Bruck Textiles
Sarah Beilby, ADA
Phillip Butler, Textor
Bill Humphries, CSIRO
Peter Cookson, Deakin University
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1. THE EVOLVING SOPHISTICATION OFTHE FIBRES SECTOR
Fibres are integral to all living things, fromthe twisted strands of our DNA to thecomplex fibrous structures that make up ourlargest mammals and trees. Life on earth
has evolved by assembling fibres and fibrouscomposites into complex materials with awide range of sophisticated properties.
To date, humankind has taken macro-fibresand developed textile materials, and thesehave become ubiquitous in our human-madeworld.
But we are nowhere near reproducing whatnature does with fibres. The emergingsciences that are enabling newnanotechnologies and biotechnologies aredriving a revolution in new materials, andfibres are poised to be at the centre of thatrevolution. Many future materials will bebased on fibres, including:
o Nanofibres
o Fibres from biopolymers (naturalor bio-derived)
o New nanofibrous composites(copying natural materialstructures)
o Complex hierarchical structuresengineered from fibrecomponents at nano, micro and
macro scales.
There are endless new applications and fibredevelopments underway, that will createnew business opportunities based on fibres.For example:
o Functional and protective apparel
o Biomedical materials including
replacement and/or regeneration ofmammalian body parts
o lightweight fibre compositesreplacing metal and concrete
structureso flexible consumer products replacing
hard plastic
o Intelligent materials from functionalfibres (eg conductive, sensory,responsive).
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Thus, the multitude of applications for fibres in todays modern economy are reflected below:
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2. FUTURE VISION FOR THEAUSTRALIAN FIBRES SECTOR
2.1.Global ActivitiesAround the world, new fibre businesses areemerging, through the efforts ofentrepreneurs exploiting scientific progress.However, stimulated by these opportunitiesand the pressures on their textilemanufacturing sectors, some first-worldcountries have already realised the emergingtrends for a more sophisticated andtechnologically advanced fibres sector, andare already taking steps to establish their
positions in a more strategic manner.
The USA has established a National TextilesCentre (NTC) that directs and supports fibreand textile research at a network of researchinstitutions. Europe has developed aStrategic Research Agenda, including 5 keyTechnology Platforms for textiles andclothing.
Australia also needs to take action. Suchactions must be lead by a vision of thefuture.
2.2.A Vision of Australias FutureFibres Sector
Australia has the potential to benefit from anexciting fibre future that could see Australianenterprises as:
o Producers of sustainable natural
fibres for global markets.
o Manufacturers of bio-derivedfibres from natural feed-stocks,using biotechnology.
o Niche manufacturers of specificnano-fibres and nano-composites, creating high value
materials and devices for exporto Manufacturers of several world-
leading textile technologiesdeveloped as innovativesolutions to Australias majorchallenges (eg in waterresources, energy, climateadaptation, transport,sustainable agriculture) andsubsequently exported to theworld.
o Specialist manufacturers thathave adapted overseas fibre and
textile advances for applicationto specific Australian issues,keeping various sectors ofAustralian endeavour in touchwith global advances.
The opportunities and benefits to theAustralian economy through such a futurefibre and fibre materials sector are profound.These are consistent with the four NationalResearch Priorities as shown in the diagram.(see over)
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Fibres Contributing Solutions to National Research Priorities
2.3 Australias ComparativeAdvantage
In broad terms, the authors believe thatAustralias relative advantages will comefrom three main drivers as highlightedbelow:
(1)Exploiting our Natural Resources
Australia has a sophisticated agriculturalsector that can provide raw materials to feeda fibres sector. For example, Australia has a:
o Demonstrable record as a worldleader in wool and cotton fibreproduction
o Proven potential to be a producer ofnext generation of sustainable fibres
o Capacity to successfully implementdemanding sustainability/greenpolicies
o Unique flora and fauna which can
provide new fibrous polymers
o Extensive experience as an early
adopter of biotechnologies forsynthesis of bio-derived fibre-forming polymers.
(2)Innovating to Meet Local andRegional Needs
Developing applications for specificAustralian needs, which can become world-class solutions that can subsequently beexported, eg:
o Water management solutions
o Climate adaptation tools
o Biomedical materials linked to ournational health needs and world-leading medical researchers.
o Fibre and textile pre-forms to createinnovative composite materials forour mining, aerospace, marinesecurity and sports technologysectors.
(3)Focussing and Redirecting ourExisting Capabilities
There is a real and significant role for a
strong fibres industry in Australia, as:
o Australia retains acomparative/competitive
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advantage in R&D in fibredevelopments
o It is needed to service local
needs
o There is scope to forge mutuallyadvantageous internationalpartnerships
o The resource base exists(human, scientific and naturalresources)
o There is a strong existingknowledge and skills base.
o High design element
o Protective and performanceapparel
o Industrial textiles
3. AUSTRALIAS POSITIONING IN THENEW WORLD OF FIBRES
This section highlights the potential forAustralia to achieve this vision of anemerging and significant fibres sector, bybuilding on the existing industry andresearch structure and capabilities.
3.1.Existing Industry CapabilityThe existing textiles/textiles product sectorprovides a strong base from which to buildthe new fibres sector. While the traditionalactivities of this sector are expected toultimately only constitute a relatively small
component of the future fibres sector, it isthe very inherent entrepreneurial nature andmarket astuteness of these traditionalplayers that will help enhance thetechnological benefits of the future fibresindustry.
Super-hydrophobic textile
surfaces out-perform the lotus
leafThe lotus leaf has an amazing capacity to keep
its surface clean and dry. By mimicking the
nano-structured surface morphology of the lotus
leaf, researchers at Deakin University have been
able to develop a range of super-hydrophobic
textiles. These textiles have a water contact
angle of over 170 degrees, which is much
higher than that of a lotus leaf. Super-
hydrophobic textiles can be used for both
apparel and outdoor applications. The method
developed at Deakin is a simple one-step
process that may be incorporated into an
existing fabric treatment process used in the
textile industry. Functionalising the surface of
conventional textiles adds significant value to
the products.
Cotton Wool
The current TCF industry has manystrengths, and that segment of industry stillsurviving has consolidated its position byexploiting these strengths, including:
o Design capability
o Fashion orientation
o Effective sourcing
o Brand management and globalsupply chain management
o Testing facilities and accreditationsystems
o Technical knowledge
o
Innovative and entrepreneurialattitude
The industry has restructured to takeadvantage of these strengths, assisted in nosmall part by the benefits of the TCFStrategic Investment Program (SIP).Companies have successfully transitionedinto brand/design/supply chain specialistsand manufacturers have found successfulniches - eg. in technical textiles, defence andhealth applications and protective textiles,and we have a textile design and fashionsector that has high profile due to itsinnovative design, niche marketing and, itsconnectivity with global supply chains.
But for the companies in this sector tobridge the gap and form part of the highpotential fibres sector of the future, a muchgreater focus will be required on innovation,R&D and commercialisation (see Figure).
A clear vision of a future fibre sector will
provide new direction and opportunities forthis creative business energy, as well asattract new investors and entrepreneurs.
The new direction needs to be sufficientlyaggressive to make use of the Research andInnovation capability within Australia tostimulate the existing TCF industry to buildon existing strengths (similar to the
European strategies) as well as nurture newstrengths of an emerging major Fibres basedsector (as offered by the NTC in the USA).This Vision extols a framework within whichboth potential new entrants and existingparties can participate, pursuing thoseopportunities which are of greatest relevanceto them, leading to renewed growth ofAustralias future fibre industry.
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Not all of the existing industry will have thecapability or desire to follow up on themarket and research developments but weneed to pursue a knowledge industryapproach and recognise that it will be adifferent industry.
New ways of processing and
using wool
The traditional ways of processing and using
wool have not changed much for well over a
century. To revitalise the wool industry, new
ways of value adding to this unique fibre must
be found.
Researchers at Deakin University and their
partners have been exploring different means
of converting wool and other natural fibres
into micro and nano particles. These fine
particles are much more reactive than theparent fibres and can be used in a range of
advanced applications.
Cotton fibre measurement
breakthrough
Scientists at CSIRO have developed an
instrument that more precisely measures
the fineness of ginned cotton fibres .
The development of the Cottonscan
technology brings the Australian and
international cotton industry significantly closer
to meeting a longstanding commercial
challenge.
Fine fibres are needed to make high-premium
lightweight fabrics but the industrys ability to
accurately grade fibre in a cost-efficient way
has presented a major problem.
Cottonscan benefits both cotton growers and
the textile industry by enabling high quality
fine Australian cotton to be correctly graded
and valued by the market.
A series of comparative tests and international
validation trials have demonstrated that the
Cottonscan instrument can quickly and
routinely measure the fineness and maturity of
cotton with high precision.
3.2.Research CapabilityAustralia is fortunate in having one of theworlds largest specialised fibre researchfacilities at CSIRO Textile and FibreTechnology, backed up by the Centre forMaterial and Fibre Innovation at DeakinUniversity and the textile, design, research
and education delivery at RMIT. In additionother Australian research institutions havebeen developing specialist researchcapabilities that involve the application offibre technology. A key feature will be thesefibre-focussed groups collaborating withresearchers and users in other fields to buildnew fibres, complex fibre composites, andspecialised applications.
Some examples of the activities of thisresearch capability that are relevant to thispaper are highlighted in the feature boxes.
3.3.Education & Training NetworkThe TCF sector has an effective establishednetwork of education and training providers,from vocational to undergraduate to postgraduate, who can adapt their training andeducation programmes to create theintellectual capital and skilled personnel topopulate this new industry.
4. STRATEGY FOR ACHIEVING THEVISION
This section has been compiled fromfeedback and ideas generated throughindustry workshops and meetings of theAdvisory Committee and Strategy Group.
Australia is well placed to capitalise on thevibrant new fibre-based developments,building on many existing and prospective
elements of comparative and competitiveadvantage.
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However, it is also important to appreciatethat Australia is in a global marketplace. Tobe competitive, our future fibre innovationswill need to be relevant to global markets toachieve the economies of scale to be pricecompetitive in both local and internationalmarkets. Since most other countries are alsolooking at many of the broad opportunitiesidentified in this paper, Australias focusmust be in areas where we have a realedge/expertise and Australia can establishitself as a world leader. Action is now neededto pursue focussed partnership projects
between industry and researchers to turnthese research priorities into commercialreality.
To best capitalise on our strengths weshould be seeking to pursue collaborativeprojects between key firms in the industry toensure the appropriate research anddevelopment occurs. An effective wayforward would be to establish consortia ofcompanies that are non-competing todevelop new strategies.
Industry will require innovations that willlead to a successful commercialisation and itwill be important to ensure that innovative
projects are supported by sound marketanalysis. ie it is vital that the commercialopportunities are real.
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Textiles encourage tissue grow th
Tissue engineering support structures known as
scaffolds are artificial devices designed to
encourage cell attachment, proliferation and
migration through the porous structure. CSIROis tailoring fibrous scaffolds for particular tissue
types. Scaffolds act as templates for attached
cells, where new tissue forms gradually and can
be implanted into the body. For a tissue
engineering scaffold to work effectively, its
structural and mechanical properties must be
suitable for the type of tissue being grown.
Using knitting, weaving, nonwovens and
electrospinning technologies, CSIRO is able to
produce fibrous scaffolds that are tubular or flat
for a variety of purposes.
This also means that we need to identify thekey regional markets that we wish topursue. For example, in general the Asianmarkets are easier for Australia to penetratethan say the US or European markets,although of course this will vary dependingon the specific product.
Some specific market opportunities arediscussed in relation to each of the threedrivers.
4.1.Exploiting our NaturalResources
Australia should seek to position itself as amajor source of unique and niche orientednatural fibre products, eg:
Maintain our position as the worldsleading supplier of apparel wool, and themost efficient cotton producer
Build on success of introducing woolfibre into unique applications, notablyprotective and performance apparel andtarget Asia with these products asAustralian products have a goodreputation there (especially in firefighting and protective wear)
The US market is also receptive toAustralian wool product wool is anoutstanding versatile fibre. (activewear/performance wear utilising wool
fibres are potential areas for innovation).
Explore scope for adding value to rareanimal fibres such as alpaca, cashmere,and mohair. These are true high fashion,high value fibres, that are produced inAustralia that offer some degree ofcomparative advantage.
Develop innovative new fibres based onour natural resources, biodiversity, andbiotechnology skills.
4.2.Innovating to Meet Local andRegional Needs
Sectors where Australia has an establishedexpertise that has a need for fibre andtextile innovations are:
- Medical devices and health
- mining industry
- automotive
- built environment and
- sustainability.
Significant R&D is already being undertaken
in Medical applications. Greater TCF industryinvolvement/participation needs to beencouraged into this sector. Increasingly the
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focus will shift to broader scale monitoring ofhealth, the prevention of cross-infection andmanaging an ageing population. Thedevelopment of textile materials throughfibre technology and the application ofsurface coatings offer innovative solutions.
The mining and minerals processing sectorsare also a significant market in Australia withall technical services divisions of the worldslargest mineral processors being based here.Fibres and textiles applications can be foundin mining operations/refineries/smeltersfrom filters to conveyor belts to protectiveapparel.
Note: A number of firms have alreadyindicated that they would be interested incollaborating on a joint project targeting themining sector. In addition, the CSIROflagship Minerals Down Under is seeking
innovative solutions for this sector.
Automotive textiles are an importantsegment with OEM manufacturers preparedto look at innovative solutions. Textiles are
used for upholstery, head lining, seats, seatbelt webbing, acoustic materials and highperformance pressure hoses. Compositetextile and fibre materials are increasinglybeing used in auto manufacturing.
Easy-breathe air filters
CSIRO has developed an electrostatic filter
that removes potentially hazardous particles
from the air.
Intermediate size particles (those with
diameters typically between 0.2 and 10
micrometers) can linger in the lungs forextended periods, during which they can
cause poisoning (if the are toxic) or allergicreactions.
Electrostatic filters have an advantage overcommonly used mechanical filters because of
the low airflow resistance. With co-funding
from Australian Wool Innovation Ltd, CSIROhas developed an electrostatically-charged
wool filter medium, which consumes little
energy, is highly efficient and makesbreathing easier.
The material has a high dust-holding
capacity and therefore a long life. It issuitable for use in air conditioning systems,
personal respirators and many other
industrial applications.
Built environment is a major fibre and textilesegment that includes domestic textiles andindustrial textiles. Advanced materials thatmake use of carbon fibres and aramids forsuperior strength are now common place.Australia has a carbon fibre and carbon
nanotube research capability that can beutilised to develop innovative applications forthe built environment, as well as in thebroader composite materials sector.
The development of products that willprovide an environmentally sustainable
outcome represents an important areawhere Australian industry can take globalleadership. Fibre recycling, development ofwater filtration and conservation, conductivefibres for renewable energy, fibrecomposites for lower weight and windturbines are some examples of sustainabilityend uses for Fibre innovations.
4.3. Focussing and Redirecting ourExisting Capabilities
The fibres sector represents an opportunity
for innovation through collaboration betweenthe Research and Innovation institutions andthe existing fibre and textile industry. Anaction plan to capitalise on the opportunitiespresented in this paper would need toaddress:
Cleaner w ater storage
A collaborative project between CSIRO, GalePacific, East Gippsland Water (EGW), and
Superspan has demonstrated the benefits of
textile covers for protecting potable waterstorages. In a two-year study, four drinking
water basins were covered with suspended
high-density polyethylene shade cloths,while two other basins were left uncovered
as controls. The study showed that the semi-
permeable covers successfully blocked lightto prevent toxic algal blooms from
photosynthesising and reduced evaporation
by 90 percent. Other benefits includedelimination of weed growth in the basins,
saving labour costs and reduction incontamination from water birds and wind
borne debris.
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an ongoing process to facilitatecollaboration between the research andinnovation institutions and industry. Thisprocess would probably best be servedby an entity that could channel fundinginto innovation projects
Identify what research is alreadyhappening, so this can be highlightedand promoted to industry
Initiate market research to identifywhere there are commercial marketopportunities. Industry needs to haveconfidence in innovation projects. eg:
(Original fabric) (Faded fabric)
UV protection to keep colour in
the fabric of life
Colour fading is a critical problem that
continues to plague the textile industry,
especially for products such as flags, awnings
and car upholstery that are exposed directlyto sunlight. Through an ARC Linkage project,
Deakin University has established research
partnership with Micronisers Pty Ltd and
Bruck Textiles Pty Ltd to develop improved
nano zinc oxide formulations that will give
o A market research document onthe industry sectors highlightedin section 4.2 would be highlyvalued.
o Surface finishing relevant tofilter fabrics and to industrial
fabricso Looking for next polymer that
will take over from existingsynthetic polymers
o An assessment of environmentalopportunities eg mulch matsare made out of polyethylenebecause of price factors, but it isnot environmentally friendly.
Identify innovation projects thatcould be developed and facilitatecollaborative partnerships toimplement an innovation project (egThe TFIAs CAPES Group provides a
good base to develop a collaborativeproject in relation to ProtectiveApparel).
Virtually all of the innovative new fibres aredeveloped outside Australia, and thereforewe need to forge close links/partnershipswith international fibre producers. Access tothe right fibre is vital for our processors andglobal networking will be an essentialcomponent of a successful Fibres innovationstrategy. Some issues that industry hasstressed that need to be addressed indeveloping a successful fibre outcome are:
The need for either a local pilot plant fordeveloping new fibres or alternatively aTechnology Agreement with a major
international fibre producer Focus must be on producing fibres that
address key Australian problems, wherewe have the recognised expertise. Thereality is that it will probably best toengage a yarn/fibre producer overseas,and then look to further processing and
finishing in Australia. Australias strength lies in developing
fibre derivations/new products and then
collaborating on these. This is somethingthat can also be accomplished with
shorter lead times (eg in fabric finishingtechnology, Australia can achieve quickgoals).
Much of the industry infrastructure hasdisappeared over time, especially withthe supply side eg strong linkages will
need to be re-established with thechemical sector
4.4Research and Education Needs
Australia has an educational infrastructure inplace that is well placed to meet industryneeds and provide vocational and higher
education graduates who can meet therequirements of a high technology fibres andmaterials industry. However, as thetraditional textiles industry has declined,industry has focused on costs andmaintenance of traditional skills and notinvested in graduates. The educationalinstitutions servicing the TCF industry haveresponded to industry restructuringpositively with an emphasis on design andsupply chains as a source of competitiveadvantage whilst continuing to providevocational , undergraduate and postgraduate programs in Textiles. To support a
robust fibre sector the technological and
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managerial base will need to be much moresophisticated.
This means the industry will need to attractnew people, with new skill sets. Goingforward the industry will need people thatare well versed in:
o Biotechnology
o Nanotechnology
o Materials engineering
o Product design
o Supply chain management
Much of this can be achieved through closerlinks with educators in other disciplines, bystimulating their interest in the excitingfuture for fibres in Australia, and by
providing specialist fibre and textile trainingto build on their existing knowledge.
In the research area, Australia is fortunateto have had an extensive and world classtextile research capability in CSIRO and atseveral Universities, developed largely to
service the Australian woolgrowing industry.Although this has declined steadily over thelast two decades, the remaining capacity isstill world class, and the key groups havealready re-aligned their activities to thevision outlined in this paper.
For Australia to fully realise the potential
opportunities outlined above, these researchgroups will need to be rejuvenated andexpanded.
A mechanism is also needed to bring CSIROand University research groups more closelytogether, to further develop and promotesynergistic effect in their research anddevelopment activities.
Carbon nanotubes could go
antiballistic
CSIRO has been granted funds under the
Defence Capability and Technology Demonstrator
Program to demonstrate the capabilities of
carbon nanotubes as strong, lightweight
antiballistic materials.
Carbon nanotubes (CNTs) are amongst the first
of the new wave of nano-structured materials
and offer extraordinary properties of strength,
stiffness and lightness.
The challenge is to capture the potential of these
new materials at the macro level. CNTs are fibres
of pure carbon that are only 1 to 100 nanometres
in diameter but up to millimetres in length.
Synthesising and manipulating these myriad tiny
fibres into ordered structures requires acombination of novel processing skills coupled
with a fundamental understanding of fibre
behaviour.
CSIRO has established a capability to produce
very highly specified CNTs with the unique
characteristic of being able to be drawn directly
into yarn. This in combination with other
advanced materials will form the basis of the new
antiballistic structures.
No single material has all of the properties
required for ballistic protection, so a successfulapplication of CNTs would see them as part of an
integrated system with greater strength and
flexibility and reduced weight.
We have a solid foundation already for avibrant new fibres sector in Australia. Thereis a lot more that fibres can offer to manyexisting industry sectors. With this visionand the right catalyst, the future is trulyfibres!
Functional bi-component
nanofibres
Researchers at Deakin University have
pioneered a technology for producing side-by-
side bi-component nanofibres from different
polymers (T. Lin &, HX Wang and XG Wang,
Advanced Materials, 17 , 2699-2703, 2005).
This technology further enhances thefunctionality of nanofibres for certain
applications and also allows the production of
the finest nanofibre materials by dissolvingone of the polymer components.
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The next generation in work wear fabric
Performance combined with durability and comfort
Bruck Bionic Gemini was developed using existing knowledge and adapting it to Australian
conditions. In Europe, the main focus is to keep the body warm without overheating. In many
parts of Australia, throughout most of the year, the main challenge is to keep the body cool. It is
clear intelligent garment construction plays a very important role in meeting that challenge, butfabric also plays a very important role.
Bruck Bionic Gemini is an intelligent fabric construction with the following features:
Fast drying
Soil release
Antimicrobial
Anti odour
High visibility
In addition to the selective use of chemicals it was crucial to test the functionality of these fabrics. Extensive tests in climate chambers and field tests conducted over several months have confirmed
that Bruck Bionic Gemini:
Releases humidity 25% faster than a similar weight100% cotton fabric
Dries 40% faster than a similar weight 100% cotton fabric
Similar cooling properties compared to a similar weight cotton fabric
All of these improvements are most importantly achieved with chemicals, which have OEKOTEX
STANDARD certification. Therefore Bruck Bionic Gemini in addition to being a high performance
fabric is also environmentally friendly and a much healthier option for theAustralian workforce.
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