Increasing resource consumption and a growing amount of textile waste increase the importance of a circular economy and recycling in the fashion and apparel industry. Environmentally friendly bio-based composites made from cellulosic fibres obtained from textile waste, and polymers based on renewable raw materials present a possible solution. In this study, the development of textile semi-finished products based on medium-to-long cotton and flax fibres obtained from textile waste in combination with a bio-based thermoplastic matrix for lightweight applications is investigated. For the production of natural fibre-polylactide hybrid yarns, fibre slivers with improved fibre orientation and blending are produced. Subsequently, quasi-unidirectional woven fabrics are produced and consolidated into bio-based composites. Textile and mechanical properties of hybrid yarns as well as bio-composites are analysed with regard to the influence of fibre length, fibre distribution in the yarn, yarn structure and fibre volume content. The results show that the production of bio-based semi-finished products can be a potential way for upcycling textile waste.
Keywords: bio-based thermoplastics; fibre waste; hybrid yarn; mechanical characterisation; natural fibre; textile waste; woven fabric.