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New “ultra-waterproof” fabric stays dry even after heavy wear

Schematic illustration of the MARS technique. Credit: Dong's Group

Scientists have developed a new type of fabric that can strongly repel water even after intense use, offering a promising solution for outdoor clothing, protective gear, and industrial materials.

A research team led by Prof. Dong Zhichao from the Chinese Academy of Sciences has created a simple one-step method to make fabrics extremely water-repellent, or “superhydrophobic.”

Their study, published in Nature Communications, introduces a new approach called MARS, short for Molecularly Assembled Robust Superhydrophobic Shell.

Superhydrophobic materials are designed so that water forms droplets and rolls off the surface instead of soaking in.

While this idea is not new, making such fabrics durable has been a major challenge.

Most existing water-repellent textiles lose their effectiveness after repeated use, washing, or friction. The protective coating often wears off quickly, especially under tough conditions.

Another issue is that many current waterproof fabrics rely on fluorochemicals, which are being restricted or banned in some countries due to environmental concerns.

Other methods can involve expensive materials or harmful chemicals, making them less practical for widespread use.

The new MARS method aims to solve these problems. Instead of coating the surface of a finished fabric, the researchers apply a protective layer directly onto each individual fiber. This creates a strong, uniform shell around every thread, making the water-repellent effect much more durable.

Tests showed that fabrics treated with this method can withstand harsh conditions while keeping their water-repellent properties.

Even after tens of thousands of abrasion cycles—simulating repeated rubbing and wear—the fabric still repelled water effectively. The material also performed well under heavy rain impact and high-speed water droplets.

To further test durability, the researchers simulated real-life use. The fabric was exposed to stretching, brushing, peeling with tape, and friction similar to backpack straps. It was even tested during activities like running and walking. In all these cases, the fabric maintained its superhydrophobic performance.

The material also proved to be highly resistant to extreme temperatures. It continued to repel water in very hot conditions, up to 160 degrees Celsius with steam, and in extremely cold conditions, down to minus 196 degrees Celsius in liquid nitrogen.

Importantly, this treatment does not affect how the fabric feels or functions in everyday use. It remains soft, breathable, and comfortable, while still allowing moisture to pass through. This balance between performance and comfort is key for real-world applications, especially in clothing.

Overall, the MARS technology offers a new path toward durable, environmentally friendly waterproof fabrics. It could be used in outdoor gear, protective clothing, medical materials, and many industrial products.

By making water-repellent fabrics stronger and more sustainable, this innovation brings us closer to clothing and materials that can truly stand up to the elements without losing their effectiveness over time.

Source: KSR.