BMBFTR 031B1489A
Abstract
Spacer fabrics, with their three-dimensional structure, are highly versatile and widely used in applications such as upholstery and performance textiles. They offer strong potential to replace conventional foam materials; however, their sustainability remains a challenge, as many spacer fabrics are still produced from fossil-based resources. Tight development timelines and strict quality requirements further limit the adoption of sustainable materials. The BioCushion project aims to develop an application-specific process for circular, sustainable spacer fabrics. Materials will be systematically cataloged, tested, and benchmarked against application requirements, and a prototype for sportswear will be developed. The resulting guide will support companies in creating more sustainable spacer fabrics by improving recyclability, reducing CO₂ emissions, and simplifying material selection.
Current Situation
Spacer fabrics are advanced textile structures characterized by their three-dimensional architecture and a wide range of adjustable parameters. Commonly used as cushioning elements, they present a promising sustainable alternative to foam-based materials. Consequently, demand for sustainable spacer fabrics is increasing across industries. Nevertheless, most spacer fabrics are still based on fossil-derived raw materials. Although innovative sustainable yarns are emerging, developers must balance environmental considerations with high performance standards and rapid development cycles. As a result, the transition to sustainable spacer fabrics is often hindered at the material selection stage due to concerns about durability and functional reliability.
Project Objective
The BioCushion project aims to develop an application-specific process description for sustainable spacer fabrics that can be implemented at an industrial scale and adapted to diverse applications. Throughout the project, available materials—especially sustainable alternatives—will be systematically analyzed, tested, and evaluated against the requirements of sectors such as upholstered furniture. In addition, a functional demonstrator in the field of sportswear will be developed to validate the performance and practicality of sustainable spacer fabrics under real-world conditions.
Approach
Current research on spacer fabrics and materials often addresses isolated aspects, making the development of sustainable spacer fabrics a complex and resource-intensive process. BioCushion addresses this challenge by creating a comprehensive, practice-oriented guideline for the development of circular and sustainable spacer fabrics. The focus lies on enhancing product recyclability and significantly reducing CO₂ emissions. By structuring and consolidating material and process knowledge, the project simplifies the selection of sustainable yarns and accelerates innovation. In doing so, BioCushion contributes to advancing sustainable spacer fabrics and supports the transition toward a more sustainable textile industry.
Project Coordinator
Textilforschungsinstitut Thüringen-Vogtland e.V. (TITV Greiz)
Project Partners
- zwissTEX Germany GmbH
- Adidas AG
Contact
Caroline Gierke
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