10. Textile Scaffold

Research

From the Textile Scaffolds course, I understand how biological nature, material science, and digital design can merge to create innovative and sustainable textiles. I have learned that biopolymers can replace synthetic materials, forming the basis for bio-composites that are renewable and biodegradable. Through leather molding, I learned how natural materials can be shaped into structured forms, while fabric formwork taught how textiles can act as flexible molds to generate different shapes. The crystallization process revealed how natural growth patterns can enhance texture and structure, and bio digital design showed how computational tools can simulate and fabricate nature-inspired scaffolds. Overall, I gained an understanding of how bio materials and fabrication can work together to redefine textile creation in a more sustainable, experimental, and regenerative way.





Fabricademy, Textile Scaffold 2025 by Anastasia Pistofidou

So based on the above understanding, this week I try to develop sustainable textile composites using worn out denim fibers, eggshell powder, sodium alginate, and glycerol. The objective was to create biodegradable, circular materials suitable for fashion and textile applications. Sodium alginate, a natural polysaccharide derived from brown algae, was selected for its film-forming and gelation properties (Rhim, 2004). Eggshell powder, rich in calcium carbonate, was incorporated to enhance rigidity and structural stability (Morsy et al., 2019). Denim fibers provided reinforcement and texture, while glycerol acted as a plasticizer to improve flexibility (Sanyang et al., 2015). The study aligns with current research trends in biopolymer composites and waste valorization for sustainable material innovation.

Experimental results confirmed that denim fibers could be effectively integrated into an alginate-glycerol matrix, forming flexible yet durable composites. Eggshell powder improved rigidity and surface texture, while glycerol enhanced elasticity. The optimal formulation balanced fiber reinforcement with polymer flexibility, producing a semi-flexible, leather-like material. These findings are consistent with previous studies on alginate-based composites reinforced with natural fibers (Kumar et al., 2020) and calcium carbonate fillers (Morsy et al., 2019). The materials demonstrated potential for use in accessories, experimental textiles, and semi-structural fashion components. I also try to make crystallization on knitted product samples.

References & Inspiration

Inspiration was drawn from the lecture of textile scaffold, biomaterial research and sustainable design practices emphasizing waste-to-resource transformation. Dominque Vial Projects of denim twist Again,

Key references included:
- Rhim, J. W. (2004). “Physical and mechanical properties of water-resistant sodium alginate films.” LWT - Food Science and Technology, 37(3), 323–330 - Morsy, M., El-Sheikh, S. M., & El-Bassyouni, G. T. (2019). “Utilization of eggshell waste in the preparation of calcium carbonate nanoparticles for reinforced composites.” Journal of Materials Research and Technology, 8(5), 5326–5334. - Sanyang, M. L., Sapuan, S. M., Jawaid, M., Ishak, M. R., & Sahari, J. (2015). “Effect of plasticizer type and concentration on tensile, thermal and barrier properties of biodegradable films based on sugar palm starch.” Polymers, 7(6), 1106–1124. - Kumar, S., Singh, R., & Singh, T. (2020). “Development and characterization of sodium alginate-based biocomposite films reinforced with natural fibers.” International Journal of Biological Macromolecules, 150, 861–870.

Tools

- Measurement tools of ingredients
- Blender and mortar for grinding eggshells and shredding denim fibers
- Mixing bowls and spatulas for combining ingredients
- Molds and trays for casting samples
- Cutting tools and measuring instruments for sample preparation
- Knitted acrylic fabric
- Sodium chloride for crystalization

Process and workflow

1. Preparation of Raw Materials:

• Collect and clean post-consumer worn out denim waste.
• Shredded denim into fine fibers.
• Washed and dried eggshells, then ground them into fine powder.

2. Formulation of Biopolymer Base:

• Dissolved sodium alginate in warm water until a smooth gel formed.
• Added glycerol to improve flexibility and prevent brittleness.
  

3. Composite Formation:

• Mixed denim fibers and eggshell powder into the alginate-glycerol solution.
• Stirred thoroughly to ensure even distribution.
• Poured the mixture into molds or spread it on trays for sheet formation.

4. Drying and Curing:

• Allowed samples to air dry for 24–48 hours at room temperature to remove residual moisture.

5. Testing and Evaluation:

• Assessed flexibility, texture, and structural integrity.

FOR Crystalization

1. Prepare the Salt Solution

• Heat the water slightly (not boiling).
• Add 7 spoons of sodium chloride to the warm water.
• Stir continuously until no more salt dissolves and a few grains remain at the bottom

2. Prepare the Fabric

• Cut the knitted acrylic fabric into the desired size.
• Make sure it is clean and free from dust or oil, as this helps the crystals adhere better.

3. Soak the Fabric

• Place the fabric in the salt solution.
• Let it soak for 10–15 minutes, ensuring it is fully saturated with the solution.

4. Remove and Arrange for Drying

• Carefully lift the fabric from the solution, allowing excess liquid to drip off.
• Lay it flat or drape it over a mold or frame, depending on the desired shape.
• Avoid wringing or squeezing the fabric.

5. Crystallization Process

• Leave the fabric to dry at room temperature in a well-ventilated area.
• As the water evaporates, salt crystals will begin to form on the surface and within the knitted loops.
• For larger crystals, allow slow drying; for finer crystals, place it in a warmer environment.

6. Observation and Finishing

• Once completely dry, observe the crystal patterns and texture.
• Handle gently, as the crystals can be fragile and may detach if rubbed.

Ingredients & Recipes

For my experiment the base formula is:
- 5 g sodium alginate
- 10 g glycerol
- 20 g shredded denim fibers
- 10 g eggshell powder
- 55 g warm water
- 7 Spoon of salt
- 250 ml warm water

RESULTS

The final product of this experiment is a semi-flexible, leather-like texture and crystalized knitted acrylic fabric. The material was lightweight, biodegradable, and visually appealing with a natural matte finish. Challenges included uneven drying and occasional cracking in thicker samples. Overall, the experiments demonstrated the feasibility of transforming jean waste and eggshells into functional textile composites using sodium alginate and glycerol as sustainable binders. Future work will focus on improving scalability, surface finishing, and water resistance.

Pattern Design of Hand Bag
Hand Bag from Textile Composite
Acrylic fibers crystalization
Embossing denim fabrics My thesis for undergraduate class
My BSc thesis centered on the design and development of a manual heat embossing machine for fabric surface finishing. I focused on creating a functional design that could imprint three-dimensional patterns on textiles using controlled heat and pressure. The work involved designing the mechanical structure and heating system to ensure uniform temperature distribution and precise pressure application. I also tested various embossing patterns and fabric types to optimize the design parameters for achieving high quality embossed effects.