Protective Textiles: Advancements, Applications, and Future Directions

Protective textiles are designed to protect individuals from a range of hazards, including extreme temperatures, chemical exposure, biological agents, and mechanical injuries [1-7]. Over the past few decades, the development of protective textiles has seen remarkable progress, driven by advances in material science, nanotechnology, and textile engineering [8,9]. These textiles are now integral to various sectors, including military, healthcare, industrial safety, and sports. The growing demand for protective textiles is fueled by the increasing awareness of occupational hazards, stricter safety regulations, and the need for enhanced performance in extreme environments [10-15]. The purpose of this paper is to provide a comprehensive overview of the current state of protective textiles, highlighting the key materials, technologies, and applications that define this field. By examining the challenges and future directions in the development of protective textiles, this paper aims to contribute to the ongoing discourse on how to improve the safety, comfort, and sustainability of these essential products.

Types of protective textiles

Protective textiles can be categorized based on the type of hazard they are designed to protect against:
Thermal protection: Thermal protective textiles are essential for environments where individuals are exposed to high temperatures, flames, or molten materials. These textiles are commonly used in firefighting gear, military uniforms, industrial safety clothing, and even in space exploration suits [16,17]. Materials such as Nomex, Kevlar, and PBI (Polybenzimidazole) are widely used due to their exceptional thermal resistance and durability. Nomex, for instance, is an inherently flame-resistant fiber that does not melt, drip, or support combustion [4,18,19]. It is used extensively in firefighting gear, where protection from flash fires is critical [20,21]. Kevlar, known for its high tensile strength-to-weight ratio, provides excellent protection against heat and flames while also offering ballistic resistance, making it a popular choice in military and law enforcement applications. In addition to these fibers, thermal protective textiles often incorporate multi-layered constructions, where each layer serves a specific purpose, such as heat insulation, moisture management, and mechanical protection [7]. The combination of these layers ensures that the textiles provide comprehensive protection while maintaining comfort and flexibility.
Chemical protection: Chemical protective textiles are engineered to resist permeation, degradation, and penetration by hazardous chemicals. These textiles are indispensable in industries where workers are at risk of exposure to toxic substances, such as chemical manufacturing, oil and gas, agriculture, and healthcare [22,23]. Materials like PTFE (Polytetrafluoroethylene) and butyl rubber are commonly used in chemical protective textiles [24,25]. PTFE, known for its non-reactive properties, is often used in chemical-resistant suits and gloves, providing a barrier against a wide range of chemicals [26,27]. Butyl rubber, with its low permeability to gases and liquids, is particularly effective against chemical warfare agents and is used in protective gloves and masks for military personnel [28,29]. Chemical protective textiles may also feature advanced barrier technologies, such as microporous membranes or laminated coatings, that enhance their resistance to chemicals while allowing moisture vapor to escape, thus reducing heat stress for the wearer [30,31]. The design of chemical protective clothing often includes sealed seams, integrated hoods, and gloves to ensure that no part of the body is exposed to harmful substances.
Biological protection: Biological protective textiles are designed to protect against exposure to biological hazards, including bacteria, viruses, fungi, and other pathogens. These textiles are critical in healthcare settings, where they help prevent the transmission of infectious diseases [32,33]. During the COVID-19 pandemic, the importance of reliable biological protective textiles was brought to the forefront [34,35]. Healthcare workers relied heavily on protective clothing such as surgical gowns, masks, and gloves to minimize the risk of infection. Antimicrobial treatments, such as silver nanoparticle coatings or quaternary ammonium compounds, are commonly applied to these textiles to inhibit the growth of microorganisms [36,37]. The development of biological protective textiles also focuses on creating breathable and comfortable fabrics that can be worn for extended periods without causing discomfort [38,39]. Innovations such as electrospun nanofibers, which can filter out pathogens while maintaining breathability, represent a significant advancement in this area.
Mechanical protection: Mechanical protective textiles are designed to protect wearers from physical injuries, such as cuts, abrasions, and impacts [40,41]. High-strength fibers like Kevlar and Dyneema are commonly used in these textiles, offering superior resistance to cutting and tearing. These textiles are widely used in protective gloves, body armor, and sportswear.
Radiation protection: Radiation-protective textiles shield wearers from harmful radiation, including ultraviolet (UV) radiation and ionizing radiation [4,6,7,13,14,15,41,42]. These textiles are used in medical, military, and industrial applications where radiation exposure is a concern. Materials such as leadimpregnated fabrics and specialized coatings are employed to achieve radiation protection.

Technological innovations in protective textiles

The development of protective textiles has been significantly influenced by advancements in materials science and textile engineering. Key innovations include:
Smart textiles: Smart textiles incorporate sensors and actuators that enable real-time monitoring of environmental conditions and the wearer’s physiological state [43,44]. These textiles are capable of detecting changes in temperature, humidity, and chemical exposure, providing immediate feedback to the wearer. Applications include military uniforms with integrated health monitoring systems and sportswear that tracks performance metrics.
Nanotechnology: Nanotechnology has opened new possibilities for enhancing the protective properties of textiles [45,46]. By incorporating nanoparticles into fibers or coatings, textiles can achieve improved resistance to water, stains, and microbial growth [47,48]. Nano-enhanced textiles are also used in creating lightweight and flexible protective clothing with superior mechanical properties.
Phase-Change Materials (PCMs): Phase-change materials are used in protective textiles to regulate body temperature. These materials absorb, store, and release heat as they transition between solid and liquid states [5,49,50]. PCMs are particularly useful in environments with fluctuating temperatures, providing comfort and protection to the wearer.
Advanced coatings and finishes: Protective textiles often feature advanced coatings and finishes that enhance their performance. For example, fire-retardant coatings can significantly improve the thermal resistance of fabrics, while water-repellent finishes protect against moisture and chemical exposure [51,52]. The development of durable and multifunctional coatings remains a key area of research in protective textiles.

Applications of protective textiles

Protective textiles find applications in various sectors, each with specific requirements and challenges:
Military and defense: The military sector has been a major driver of innovation in protective textiles. Soldiers require clothing that offers protection against ballistic threats, chemical and biological agents, and extreme weather conditions. The development of lightweight, durable, and multifunctional textiles is essential for enhancing soldier performance and safety.
Healthcare: In healthcare, protective textiles are vital for infection control and patient safety. Surgical gowns, masks, and drapes are designed to prevent the spread of pathogens, while antimicrobial textiles reduce the risk of hospital-acquired infections. The COVID-19 pandemic has underscored the importance of reliable protective textiles in healthcare.
Industrial safety: Workers in hazardous industries, such as construction, mining, and chemical processing, rely on protective textiles to minimize the risk of injury and exposure to dangerous substances. Industrial safety clothing must meet stringent standards for durability, comfort, and protection, often requiring the use of specialized materials and construction techniques.
Sportswear: In sports, protective textiles are used to enhance performance and prevent injuries. Impact-resistant textiles, such as those used in protective gear for contact sports, are designed to absorb and dissipate energy, reducing the risk of injury. Additionally, moisture-wicking and temperature-regulating textiles improve comfort and performance in various sports.

Challenges and future directions

Despite significant advancements, several challenges remain in the development of protective textiles. These include:
Balancing protection and comfort: Achieving the right balance between protection and comfort is a persistent challenge. High-performance protective textiles are often bulky and restrictive, which can limit mobility and comfort. Ongoing research aims to develop materials that offer maximum protection without compromising comfort.
Sustainability: The environmental impact of protective textiles is a growing concern. The production of high-performance textiles often involves the use of non-renewable resources and hazardous chemicals. Developing sustainable alternatives, such as biodegradable fibers and eco-friendly coatings, is a priority for the industry.
Customization and personalization: The demand for customized protective textiles is increasing, particularly in sectors like healthcare and sports. Advances in 3D printing and digital textile technologies offer new possibilities for creating personalized protective gear tailored to individual needs.
Regulatory standards: Protective textiles must meet rigorous regulatory standards to ensure their effectiveness and safety. Harmonizing standards across different regions and industries remains a challenge, particularly as new materials and technologies emerge.

Protective textiles are essential in safeguarding individuals from a wide range of hazards, with applications spanning multiple industries. Advances in materials science, nanotechnology, and smart textiles have significantly enhanced the protective capabilities of these textiles. However, challenges such as balancing protection and comfort, ensuring sustainability, and meeting regulatory standards continue to drive research and innovation in this field. The future of protective textiles lies in the development of lightweight, multifunctional, and sustainable materials that offer superior protection and comfort, meeting the evolving needs of various industries.

The authors have no relevant conflicts of interest to disclose.

The authors declare that no funds, grants, or other support were received during the preparation of this manuscript.

Technical supports from the “ZR Research Institute for Advanced Materials”, Sherpur-2100, Bangladesh are gratefully acknowledged.

1. Pal P (2017) Industry-specific water treatment. Industrial Water Treatment Process Technology, Elsevier, pp: 243-511.
2. Azanaw A, Birlie B, Teshome B, Jemberie M (2022) Textile effluent treatment methods and eco-friendly resolution of textile wastewater. Case Studies in Chemical and Environmental Engineering 6: 100230.
3. Bauer C, Jacques P, Kalt A (2001) Photooxidation of an azo dye induced by visible light incident on the surface of TiO₂. Journal of Photochemistry and Photobiology A: Chemistry 140(1): 87-92.
4. Khan M, Saeed MA, Ullah S, Repon MR, Pranta AD, et al. (2024) Development of self-cleaning and antibacterial properties on cotton fabric using silver nanoparticles and PFOTS. SPE Polymers 5(4): 568-575.
5. Hosen MI, Pranta AD, Hasan MM, Islam MS, Islam T, et al. (2024) Preparation and application of black cumin seed oil emulsion with enhanced stability for antimicrobial treatment of cellulosic fabric. Fibers and Polymers 25(7): 2617-2627.
6. Motaleb KZMA, Repon MR, Pranta AD, Milašius R (2024) Enhancing mechanical properties of natural waste-based composites for automobile and plastic industry. Polym Compos 45(14): 13113-13126.
7. Akter N, Repon MR, Pranta AD, Islam S, Khan AA, et al. (2024) Effect of cotton-polyester composite yarn on the physico-mechanical and comfort properties of woven fabric. SPE Polymers 5(4): 557-567.
8. Rautio T, Ohinmaa A, Perälä J, Ohtonen P, Heikkinen T, et al. (2002) Endovenous obliteration versus conventional stripping operation in the treatment of primary varicose veins: A randomized controlled trial with comparison of the costs. J Vasc Surg 35(5): 958-965.
9. Colombi BL, Siqueira Curto Valle R, Borges Valle JA, Andreaus J (2021) Advances in sustainable enzymatic scouring of cotton textiles: Evaluation of different post-treatments to improve fabric wettability. Clean Eng Technol 4: 100160.
10. McMullan G, et al. (2001) Microbial decolourisation and degradation of textile dyes. Appl Microbiol Biotechnol 56(1–2): 81-87.
11. Rizvi H, Ahmad N, Yasar A, Bukhari K, Khan H (2013) Disinfection of UASB-treated municipal wastewater by H₂O₂, UV, Ozone, PAA, H₂O₂/sunlight, and advanced oxidation processes: Regrowth potential of pathogens. Pol J Environ Stud 22(4): 2013.
12. Saha J, Ara MR, Pranta AD, Hossain MS (2024) Antimicrobial and antioxidant functionalization of cellulosic fabric via mushroom and neem oil treatment: A step toward sustainable textiles. Journal of Vinyl and Additive Technology.
13. Saha J, Ara MR, Pranta AD, Hossain MS (2024) Antimicrobial and antioxidant functionalization of cellulosic fabric via mushroom and neem oil treatment: A step toward sustainable textiles. Journal of Vinyl and Additive Technology.
14. Ahmed F (2024) Eco-sustainable printing of cellulosic polymeric material using bio-colorants and bio-crosslinkers. SPE Polymers.
15. Motaleb KZMA, Pranta AD, Repon MR, Karim FE (2024) Preparation and characterization of MgO-based composites: Analysis of moisture, corrosion, and fungal resistance, and mechanical properties. Constr Build Mater 447: 137926.
16. Wakelyn PJ (2008) Environmentally friendly flame-resistant textiles. Advances in Fire Retardant Materials, pp. 188-212.
17. Peng H, Wang D, Li M, Zhang L, Liu M, et al. (2019) Ultra-small SiO₂ nanospheres self-pollinated on flower-like MoS₂ for simultaneously reinforcing mechanical, thermal and flame-retardant properties of polyacrylonitrile fiber. Compos B Eng 174.
18. Rault F, Giraud S, Salaün F (2015) Flame retardant/resistant based nanocomposites in textile. Engineering Materials, Springer Science and Business Media, pp. 131-165.
19. Mastalska-Popławska J, Wójcik L, Izak P (2023) Applications of hydrogels with fire retardant properties-a review. Journal of Sol-Gel Science and Technology 105: 608-624.
20. Sharma NK, Verma CS, Chariar VM, Prasad R (2015) Eco-friendly flame-retardant treatments for cellulosic green building materials. Indoor and Built Environment 24(3): 422-432.
21. Mohamed AL, Hassabo AG (2015) Flame retardant of cellulosic materials and their composites. Engineering Materials, Springer Science and Business Media, pp. 247-314.
22. Zi-Xiang Z, Si C (2023) The mathematical study of compression behaviours of silicone rubber composites reinforced by warp-knitted spacer fabrics. Industria Textila 74(3): 303-309.
23. Alı A, Mehmet K, Alı B, Seçgın K (2023) Evaluation of the mechanical properties of chopped carbon fibre reinforced polypropylene, polyethylene, polyamide 6, and polyamide 12 composites. Industria Textila 74(2): 175-183.
24. Alim MA, Moniruzzaman M, Hossain M, Wahiduzzaman, Repon M, et al. (2022) Manufacturing and compatibilization of binary blends of superheated steam treated jute and poly (lactic acid) biocomposites by melt-blending technique. Heliyon 8(8).
25. Mishfa KF, Alim A, Repon R, et al. (2024) Preparation and characterization of snake plant fiber reinforced composite: A sustainable utilization of biowaste. SPE Polymers 5(1): 35-44.
26. Bradu P, Biswas A, Nair C, Sreevalsakumar S, Patil M, et al. (2023) Recent advances in green technology and Industrial Revolution 4.0 for a sustainable future. Environmental Science and Pollution Research 30(60): 124488-124519.
27. Kibert CJ, Sendzimir J, Guy B (2010) Construction ecology and metabolism: Natural systems as analogues for a sustainable built environment. Construction Management & Economics 18(8): 903-916.
28. Ramakrishna S, Mayer J, Wintermantel E, Leong KW (2001) Biomedical applications of polymer-composite materials: a review. Compos Sci Technol 61(9): 1189-1224.
29. Bhong M (2023) Review of composite materials and applications. Mater Today Proc.
30. Ku H, Wang H, Pattarachaiyakoop N, Trada M (2011) A review on the tensile properties of natural fiber reinforced polymer composites. Compos B Eng 42(4): 856-873.
31. Khalid MY, Al Rashid A, Arif ZU, Ahmed W, Arshad H, et al. (2021) Natural fiber reinforced composites: Sustainable materials for emerging applications. Results in Engineering 11: 100263.
32. Bucić-Kojić A, Planinić M, Tomas S, Jakobek L, Šeruga M (2009) Influence of solvent and temperature on extraction of phenolic compounds from grape seed, antioxidant activity and colour of extract. Int J Food Sci Technol 44(12): 2394-2401.
33. Kafle K, Greeson K, Lee C, Kim SH (2014) Cellulose polymorphs and physical properties of cotton fabrics processed with commercial textile mills for mercerization and liquid ammonia treatments. Textile Research Journal 84(16): 1692-1699.
34. Mondal MIH, Saha J (2019) Antimicrobial, UV resistant and thermal comfort properties of chitosan- and aloe vera-modified cotton woven fabric. J Polym Environ 27(2): 405-420.
35. Azmana M, Mahmood S, Hilles AR, Rahman A, Bin Arifin MA, et al. (2021) A review on chitosan and chitosan-based bionanocomposites: Promising material for combatting global issues and its applications. Int J Biol Macromol 185: 832-848.
36. Wisniak Ben J (2023) Dyes: From antiquity to synthesis. Indian Journal of History and Science.
37. Bulut MO, Baydar H, Akar E (2014) Ecofriendly natural dyeing of woollen yarn using mordants with enzymatic pretreatments. Journal of the Textile Institute 105(5): 559-568.
38. Chen L, Zhao X, Tang O, Price L, Zhang S, et al. (2017) Supply chain collaboration for sustainability: A literature review and future research agenda. Int J Prod Econ 194: 73-87.
39. Valor C (2007) The influence of information about labour abuses on consumer choice of clothes: a grounded theory approach. Journal of Marketing Management 23(7-8): 675-695.
40. Sun JJ, Bellezza S, Paharia N (2021) Buy less, buy luxury: Understanding and overcoming product durability neglect for sustainable consumption. J Mark 85(3): 28-43.
41. Chowdhury MAA, Rahman MM, Dey M, Moudud-Ul-Huq S, Hossain SA (2023) Perceived pressures and motivations for environmental disclosures: Role of certification. Sage Open 13(4).
42. Abdelmeguid A, Afy-Shararah M, Salonitis K (2024) Towards circular fashion: Management strategies promoting circular behaviour along the value chain. Sustain Prod Consum 48: 143-156.
43. Govindan K, Azevedo SG, Carvalho H, Cruz-Machado V (2014) Impact of supply chain management practices on sustainability. J Clean Prod 85: 212-225.
44. Styles D, Schoenberger H, Galvez-Martos JL (2012) Environmental improvement of product supply chains: A review of European retailers’ performance. Resour Conserv Recycl 65: 57-78.
45. Timo (2011) Rissanen, shaping sustainable fashion: changing the way we make and use clothes. Earthscan.
46. Öşmal E, Yildirim L (2015) Non-apparel applications of denim. Denim: Manufacture, Finishing and Applications, pp. 507-526.
47. Hollingsworth J, Focus E. Environmental impact of the clothing industry.
48. Maryan AS, Montazer M (2013) A cleaner production of denim garment using one step treatment with amylase/cellulase/laccase. J Clean Prod 57: 320-326.
49. Samanta AK (2018) Application of natural dyes to cotton and jute textiles: Science and technology and environmental issues. Handbook of Renewable Materials for Coloration and Finishing, wiley, pp. 213-277.
50. Pizzicato B, Pacifico S, Cayuela D, Mijas G, Riba-Moliner M (2023) Advancements in sustainable natural dyes for textile applications: A review. Molecules 28(16): 5954.
51. Geelani SM, Ara S, Mir NA, Bhat SJA, Mishra PK (2017) Dyeing and fastness properties of Quercus robur with natural mordants on natural fibre. Textiles and Clothing Sustainability 2(1).
52. Ammayappan L, Jose S, Arputha Raj A (2016) Sustainable production processes in textile dyeing. Environmental Footprints and Eco-Design of Products and Processes, Springer, pp. 185-216.