spunlace

Spunlace, also known as hydroentangled nonwoven, is a fabric formed by entangling fibers with high-pressure water jets. A web of fibers is laid on a moving forming screen; an array of precisely oriented jets projects water at high pressure, which interlocks the fibers and binds the web into a coherent fabric without chemical binders or heat. The process can use staple or short fibers in dry-laid webs and yields fabrics with a soft hand, good drape, and varying absorbency and strength depending on fiber type, basis weight, and bond density. Common fibers include polyester, polypropylene, viscose, cotton, and blends.

Applications: Spunlace fabrics are widely used in consumer wipes (baby wipes, cosmetic wipes), hygiene and disposable medical products (drapes, gowns, wound dressings), as well as in interlinings, home textiles, and automotive interiors. They can be engineered for different porosities, textures, and levels of wet strength.

Process details: Web formation occurs on a conveyor or belt, followed by hydroentangling: a nozzle array directs jets onto the web to entangle fibers. Control of jet pressure, nozzle geometry, and web structure determines fabric properties. Post-processing may include drying, calendaring, embossing, and finishes such as softeners or antimicrobial treatments.

Advantages and limitations: Advantages include elimination of binders and heat, strong softness and drape, and tunable performance. Limitations involve higher water and energy use, need for wastewater treatment, and equipment costs; material costs depend on fiber type and desired properties.

Environmental considerations: Spunlace can utilize natural, recycled, or synthetic fibers. Water management and effluent treatment are important, and the end-of-life options vary with fiber blends and finishes.