The Filament and Textile Technology Lab provide integrated capabilities for polymer compounding, custom filament extrusion for 3D printing, fiber and yarn formation, and advanced textile material development. The facility supports the full pathway from pellet conditioning, compounding and small-quantity extrusion to pilot-scale multifilament and bicomponent filament production, winding, air texturizing, crimping, cutting, pleating, steaming and lamination.

The lab serves researchers and industry by enabling the development and evaluation of custom 3D-printing filaments, engineered bicomponent yarns, air textured yarns, staple fibers and laminated textile structures for prototyping, process optimization and specialty material applications.

List of Unique Capabilities

• Custom thermoplastic filament extrusion for additive manufacturing (3D Printing), prototyping and specialty material development.
• Small-quantity polymer compounding and extrusion to support experimental research, early-stage material screening, formulation trials and processability evaluation.
• Pilot-scale multifilament and bicomponent yarn production with flexible filament configurations for engineered fiber and yarn development.
• Yarn winding, air texturizing, and crimping to modify yarn structure, improve handling properties and support downstream textile processing.
• Tow cutting and staple fiber preparation for converting continuous filament tow into staple fibers for textile, nonwoven and specialty material applications.
• Pleating, steaming and thermal lamination to support downstream textile shaping,

List of Equipment

• The Hills Bicomponent Melt-Extrusion Machine is a pilot-scale system for producing thermoplastic continuous filament yarns from mono and bicomponent polymers. The system can produce 72-, 144- and 288-filament yarns and supports different bicomponent cross-sectional configurations such as sheath/core, eccentric sheath/core, side-by-side and islands-in-the-sea. The line is supported by Conair and Novatek resin dryers for pellet conditioning before extrusion and a Leesona 967 Winder for controlled filament yarn take-up. This integrated setup supports the pathway from polymer drying and bicomponent melt extrusion to yarn winding, enabling research, process development and pilot-scale production of engineered multifilament yarns.
• The lab-scale vertical and horizontal extruders provide compact melt-extrusion capabilities for producing filament yarns from limited material quantities. With single-hole and seven-hole die configurations, these systems support both monofilament and small multifilament trials with nominal filament diameters ranging from 0.2 to 0.5 mm. They are well suited for early-stage material screening, filament prototyping, process development, and evaluation of novel or limited-quantity feedstocks before scale-up to larger extrusion or spinning systems.
• The CW Brabender Mixing Extruder is a lab-scale single-screw extrusion system for melt processing, compounding and filament extrusion of thermoplastic materials. The system includes conventional and two-mixing-zone screw configurations, allowing both standard extrusion and enhanced melt mixing. An automatic feedstock mixer and feeder support consistent material feeding and improved formulation uniformity during processing. With 2, 3 and 4 mm dies, air- and water-cooling options, and a filament chopper for pelletizing extrudates, this system is well suited for custom filament development, formulation screening, process optimization and small-batch pellet production. The equipment is suitable for developing 3D printing filament via two-step process that include compounding polymer and micronized fibers or particles and then filament extrusion.
• SMM Stähle-Eltex Air Texturizing Machine is used to convert continuous multifilament yarn into air textured yarn (ATY) by feeding the yarn through an air-jet nozzle, where compressed air creates loops, entanglement and bulk. The result is a yarn with a more spun-like appearance, higher bulk, softer hand and improved cover, typically without stretch compared to false-twist textured yarns.
• The Turbo Crimper is used to introduce mechanical crimp into continuous filament or tow, giving the material more bulk, cohesion, loft and textile-like handling properties. The DM&E Series 40 Cutter is a tow cutter used to cut continuous filament tow into staple fiber of controlled length. This two equipment can be used together or independently.
• Cibitex – EASY STEAM II, D-0017 is a textile steaming unit used for steam fixation and post-treatment of printed fabrics, especially fabrics printed with reactive and acid ink chemistries.
• Muratec Winder is a one-position yarn winding unit to backwind from larger packages to smaller packages with desired yarn length. 
• Practix OK-12 L Seamless Teflon Belt Drum Laminator is a thermal drum laminating system used to bond fabrics and other flexible materials under controlled heat and pressure. With its seamless Teflon belt, heated drum and pressure-roll configuration, the system is suitable for producing fabric-reinforced laminates. It is well suited for process development and pilot-scale production of laminated textile structures requiring uniform bonding and thermal control. Additionally, it serves as dryer and presser with set temperature for dye sublimation and ink fixation processes.
• 3D Printers Range of desktop 3D printers are available for producing parts from polymer and fiber-reinforced (continuous or micronized fiber) commercial or in-house developed printable filaments. Examples of print filaments include Onyx, Nylon, Precise PLA and Smooth TPU 95A, and micronized cellulose fiber/PLA.

Contact

Abdel-Fattah Seyam, Charles A. Cannon Professor of Textiles | aseyam@ncsu.edu

Tri Vu, Specialty Trades Technician | tdvu@ncsu.edu