2021 Senior Design Booklet by NC State Wilson College of Textiles

Senior Design

2022

Textile Engineering and Textile Technology

Table of Contents Program Directors 4 TA Bios and Thanks 6 2021-2022 Sponsors 7 Course Overview 8 The Rice Bag Challege 9 How to Get Involved 10 Group Projects 12 Textile Engineering Program 38 Textile Technology Program 39 3

Program Directors

Russell E. Gorga (Ph.D., Iowa State University, Chemical Engineering) is a professor in the Department of Textile Engineering, Chemistry and Science at the NC State University and former program director of textile engineering. His main interests lie in developing polymer nanocomposites with improved properties (mechanical and conductive) for a variety of functional applications. Before coming to NC State, Dr. Gorga was a postdoctoral associate at MIT where he worked on improving the strength of brittle polymers (such as poly (methyl methacrylate)). In addition, Dr. Gorga worked as a research engineer at Union Carbide Corporation from 1997 through 2000, where he focused on structure-property relationships of semi-crystalline polymers for high strength

Amanda C. Mills (interim co-director) (Ph.D., NC State University, Mechanical Engineering) is an assistant research professor in the Department of Textile Engineering, Chemistry and Science at the NC State University. Her focus is on developing innovative methods for electronics integration into textiles. She creates full system demonstration platforms to examine the impact of the textile on the device and vice versa. For example, this has included system level electronic designs and knit structure designs for human energy harvesting and physiological sensing.

TA Bios and Thanks Caitlin Knowles (B.Eng. Olivia Turschak (B.S. Textile Materials Engineering, McGill Technology, North Carolina State University) is a Ph.D. candidate University) is a master’s student in studying fiber and polymer science textile engineering at the Wilson at the Wilson College of Textiles. College of Textiles. She has been Her research is on the design and communication of a TA for the Senior Design program for the past two smart textile products with a focus on 3D garment years and serves as the laboratory assistant in the simulation and system design, under the supervision ZTE Weaving Lab. of Professor Jesse Jur. Coby Hart (B.S. Textile Engineering, NC State University) is a master’s student studying textile engineering at the Wilson College of Textiles. His research and personal interests span many topics from sustainable materials innovation, to advanced yarn manufacturing technologies and electronic textiles characterization.

Beomjun Ju (M.S .Textile Science, Seoul National University) is a Ph.D. candidate studying fiber and polymer science at the Wilson College of Textiles. His research is on the printing of electronic textile and the integration of sensors, interconnects, energy harvesters based on textile, under the supervision of Professor Jesse Jur.

Zeis Textiles Extensions (ZTE) Staff: •Jenna DeCandio, Knitting Lab Manager •William Barefoot, Weaving Lab Manager •Tim Pleasants, Spinning Lab Manager •Jeffrey Krauss, Dyeing and Finishing Lab Manager •Teresa White, Physical Testing Laboratory Specialist

Special Thanks: TECS Admin staff, Allison Blanchard, Joyce Cole, Beth Palmer and the North Carolina Textile Foundation.

2021-2022 Sponsors

Course Overview This capstone in the Department of Textile Engineering, Chemistry and Science provides companies the opportunity to work with student teams to innovate in product and/or process development. In working with the student teams, companies explore materials property design, develop new directions for existing products or take their materials/product into a new marketspace. Our students utilize their expertise in engineering fundamentals, information systems, medical textiles, product development, supply chain management, testing and consumer behavior to solve a current product/process challenge. Through sponsored projects, student teams will learn project management and product design principles that leverage the global textile complex.

Project Expectations and Outcomes The purpose of this course is to deliver a ‘real-world’ experience that prepares students to solve open ended problems that they will face upon entering the workforce. The sponsored student team is expected to: •Communicate effectively on the project problem, objectives and proposed solutions. •Work efficiently in teams to deliver high-performing results. •Assess, select and learn the latest and most appropriate technologies for project success and be able to adapt those technologies as needed. •Analyze the project and solution from financial, economic, technical, ethical and commercial perspectives. •Develop ideas with appropriate patent mapping and intellectual property assessment. •Produce proof-of-principles prototype(s).

The Rice Bag Challege The annual Rice Bag Challenge is sponsored by Rise Against Hunger, an international organization that annually distributes millions of meals around the world through community meal-packing events. Each Senior Design team was given one week to create a useful prototype that would solve a problem in developing areas around the world using a maximum $10 budget and two, 50 pound rice bags. At the end of the week, each team pitched their product to a team of judges from Rise Against Hunger. This year our top three products are: First Place: Utility Apron designed by Rachel Argabright, Bailey Bush and Laura Potok Second Place: Hanging Planter designed by Emily Odykirk, Jessica Schwendeman and Kayla Wyatt Third Place: Cot designed by Jacqueline Ashford-Lavy, Brandon Postema-Drolet and Chris Watts

How to Get Involved Sponsor Requirements

While most sponsors spend an average of one to two hours per week on the project, many find interaction with the students to be the most rewarding aspect. Beyond that minimal time commitment, other expectations include: • Helping define project scope and metrics for project success. • Holding regular meetings with the team and providing specific project feedback. • Providing technical mentoring and feedback on the team’s materials and process deliverables. • Providing specific training on unique tools that are pertinent to the project. • Providing coaching to help the student team reach the best solutions.

Keys to Success for a Sponsor

• It is important for the sponsor not to tell the team exactly what to do. This is an open-ended problem. • Address any issues as they arise. If you encounter team issues or technical project issues, contact the program directors immediately. •Encourage information sharing. Visit NC State and schedule times for the team to visit your company. Consider introducing the team to your company in mid-October and bringing them back at the end of March to present their hard work.

Project Submission

The project submission period is March 1 to July 1. Prior to submission, two short phone interviews are required with the Senior Design co-directors. This helps to identify the project scope and determine if the project fits well with our students’ skill sets. Sponsors are notified of project acceptance by August 20, and projects begin the first day of classes in mid-August.

Selection of Student Teams

Student teams are carefully selected based on their project interest, complementary skill sets and leadership style inventory. Each year, 45 to 60 students participate in the program, forming 12 to 18 teams of three to four students per team.

Project Management

The rigorous Senior Design capstone program spans both fall and spring semesters. Course directors guide the teams through a design process to develop innovative products/processes that meet the projects’ defined criteria and constraints.

Financial Commitment

A required donation of $10,000 is due by the end of September. This contribution supports project expenses as well as strategic growth of the capstone lab space and program.

Intellectual Property and Confidentiality

When a project is funded by a donation, NC State does not exert intellectual property (IP) ownership unless an NC State employee is involved; undergraduate students in this course are not NC State employees. The IP generated from the project is owned by the students unless otherwise agreed upon with the sponsor in the form of a non-disclosure agreement between the two parties at the onset of the project. Existing inventions and technologies are the separate property of the sponsor company or NC State. Sponsored research agreements are also available. Two public presentations by the team are made each year -- one in the fall semester and another in the spring semester. Teams are required to review content with the sponsor before this presentation.

Design Showcase

The culmination of the course is a “Design Day” poster session generally held in April at NC State.

Avec | Sock Design for Posture Alignment Ryan Darden, Marissa Noon, Robert Seevers Sponsored by Avec Performance, this senior design team was tasked with the design and development of a sock intended to correct and improve the foot posture of the wearer.

Micheal Jordan, a sports therapist and cofounder of Avec Performance with Robert Montano, has developed a taping technique that corrects posture of the foot and ankle, effectively stacking the hips and knees over the feet to reduce pain in the back and up to the shoulders. The team benchmarked a number of different products on the market and developed knit structures focused on stability and compression as well as structures that excelled in comfort and breathability. Using information gathered from tensile tests as well as evaluations of covering factor and comfort, the team worked with Jenna Decandio, knitting lab manager at the Wilson College’s Zeis Textiles Extension, to develop initial prototypes for experimental testing. This series of prototypes was evaluated based on the interface pressure applied at the tarsal bone region. The team used these experimental results to establish and produce the final design. The team would like to thank Jenna Decandio, Dr. Amanda Mills, Dr. Russell Gorga, Teresa White, Micheal Jordan and Robert Montano for this project’s success.

PVH | Next Life Underwear Recycling Molly Humphrey, Claire Henson, Chenlu Hou, Yu Yan

The Next Life Underwear Project focuses on developing multiple sustainable downcycling solutions in collaboration with team sponsor PVH using their post-consumer takeback undergarments. Over the fall and spring semesters, the team has worked to bring the ideation process into physical prototypes using a unique array of methods. Unlike most groups, the Next Life Underwear team tackled not just one prototype, but several different ones that utilized technology from the knitting lab, paper science department, Nonwovens Institute and polymer and color chemistry program.

Over the course of the school year, the prototype concepts evolved through a process of scientific trial and error until the team was able to narrow down deliverables to three main product categories: knit bra pad cover, recycled cotton paper hang tag and recycled PET button. Although the team had several subcategories under each main product category, these products are most fully developed through quality and property testing achieved with the help of the Wilson College of Textiles lab facilities. Furthermore, each of these products conveys a recycling story that can be observed by the consumer since they have been conceived of completely recycled materials and would be used in place of the currently used virgin materials. Some of the prototypes, such as the recycled PET yarn used to make knit structures, were produced in collaboration with companies such as UNIFI, whereas other prototypes, such as the composite button and paper hang tag, were produced fully with campus facilities by our team and faculty members. Thanks to the ample resources provided in the Senior Design lab as well as the Wilson College, the Next Life Underwear team was able to bring a multitude of ideas to life that PVH will hopefully implement within the company and use to springboard the development of even more sustainable solutions.

The North Face | Alternate Ripstop Construction Jacqueline Ashford-Lavy, Brandon Postema-Drolet, Chris Watts

For our Senior Design project, we were tasked by The North Face to create an alternative ripstop design. Ripstop fabric was utilized in World War II, where it was first proposed that it would be beneficial for a variety of uses. The U.S. Army’s combat uniforms were in need of fabric that would be resistant to tears and rips on the battlefield, while the Air Force was looking for an equally strong yet light material that could replace the expensive and delicate silk used in parachutes. Even then, ripstop fabric was a plain weave with reinforcement yarns around them.

The North Face presented the project to create new aesthetic weave designs that provide enhanced performance characteristics, specifically strength and abrasion resistance, compared to a traditional ripstop design. The project is based on the group’s research by creating the control fabric and then creating five different weave designs that are visually different and appealing when compared to the traditional ripstop design. We decided on these five different designs based on different geometric shapes. These five weave designs including the control were created with 100% virgin, 100 denier polyester. The process of getting the weave designs woven through an outsourced mill allowed us to experience communicating professionally like we were customers trying to have a fabric made. Throughout the year-long course, we had to determine which weave design was the strongest by performing a variety of tests. These tests included abrasion, tensile, tongue tear and Elmendorf tear. We then performed these tests again on the same fabric after it had been washed three and ten times. The data from these tests were then analyzed and used to determine if the weave designs we created were stronger than the traditional ripstop design.

Under Armour | Novel Fiber Implementation Stephanie Gongora, Bernie Igba, Rachel Klenke, Alyssa Phan

Our sponsor, Under Armour, has a new fiber called Bexloy. Bexloy is a recyclable elastic fiber that has the potential to replace Spandex in Under Armour’s garments to make it recyclable. We have been tasked with characterizing Bexloy among products on the market in order to discover what types of garments Bexloy would be best suited for. We have been given multiple iterations of the Bexloy fabric to test. The fabrics have gone through tensile, cyclic loading, heatforming and sewability tests. During the past eight months, we have gone through the development process from ideation to prototyping. Initially, it took us some time to grasp the scope of the project and come to a consensus on aspects to test, but once we did, it was full steam ahead. During the fall, we tested the Bexloy fabric against different running leggings on the market. After reviewing the data, we concluded that at the current stage, Bexloy would be better used for base layer garments such as a compression shirt or short.

During the spring semester, we focused primarily on this idea, comparing the Bexloy fabric to running tights, sustainable compression shorts and athletic long-sleeved tops. After much testing, we have decided that our final prototype will be a shirt made out of the best of three fabrics we asked Under Armour to knit for us based on the research we conducted throughout the year. Throughout the project there have been many lessons learned from the very beginning up until the end. Working as a team has been one of the most important lessons from this project. Being able to work with members of the team in parallel to get tasks done and making team decisions is important in a project like this. Understanding the strengths of each team member and delegating tasks to the best person fit for the job has been an important pillar for our success as a team. While teamwork has been crucial, flexibility has been just as important of a lesson. With a dynamic and changing project scope, being flexible and constantly coming up with new ideas on how to best carry out the goals of the project has been a large part of both semesters. Along with teamwork and flexibility, our project required an abundance of different tests to characterize the unique features of the Bexloy fiber. Conducting tests everywhere from unique tensile tests to chlorine resistance testing has given each team member hands-on experience that will transfer to jobs and projects in the future.

Stryker | Visual Brand Language on Fluid Proof, Breathable Mattress Covers Kezia Johnson, Tashana Flewwellin, Nick Dimarco Our team has been tasked by Stryker to create a mattress that not only conveys Stryker’s Visual Brand Language (VBL) but can also withstand the normal wear and tear and standard hospital cleaning procedures. Visual Brand Language is identified by the visual and textural representation of a product that is related to the brand identity or proper product application. Previous Stryker mattresses have run into problems with peeling of the visual brand language, degradation/yellowing of the polyurethane cover, staining due to cover construction and ink bleeding with their printing methods.

With this information, the team saw the project consisted of three components: coatings, ink/ pigments and printing methods. The project process started with a series of tests performed on a variety of Stryker mattress samples containing various (layering) constructions and materials. From the initial tests, the team narrowed down which sample and material to work with further. The team further explored the polyester knit Stryker sample that uses sublimation print, with either a silicone or polyurethane coating on top as the first prototype. The next step was to test the coatings by applying them directly onto the selected Stryker mattress sample. When that prototype failed, the team decided to layer the materials of the mattress one by one. The team created the second prototype with a polyester knit fabric that uses thermal fixed dyes to convey the visual brand language and coated with a clear silicone coating. The team wanted to focus on keeping the original polyester knit fabric currently used by Stryker but change the printing method and the coating’s opacity and thickness. This mattress construction achieved a bleach and stain resistant cover with the highest resolution VBL.

Lear Corp. | Sustainable Polyester for Automotives Jessica Hoover, Arabella Ball, Emma Tilley

The scope of our project is to compare biobased, biodegradable, virgin and recycled polyester yarn types to determine which type will be more sustainable from cradle-to-gate as well as maintaining excellent automotive performance. We are attempting to define a life cycle assessment for the yarn types to understand the environmental impacts of each yarn type from cradle-to-gate. We selected car seats to be the focus of our research and testing and had fabric produced to meet specifications that make it ideal for that application. Additionally, we are having car seat pads made so that we can have a physical display of our fabric and a represenation of how it would look in an actual car.

During this time, we have had biweekly meetings with our sponsor at Lear Corporation to provide updates on our project as well as receive feedback and trade suggestions. We have also visited the Guilford Mills facility several times to receive fabric samples and fabric information as well as to finalize our testing plan. As our fabric testing plans were being finalized, we were also researching information so that we could conduct our life cycle assessment and reaching out to our yarn suppliers so that they can provide information as well. We completed an analysis of the fabric’s performance with its sustainability score to evaluate which fabric is the best for a car seat. During this project, we have gained valuable experience in working as a team on developing and carrying out a year-long project. We have learned how to develop a testing plan, how to work different types of equipment and software and how to interpret those results. We developed our communication skills and other interpersonal skills. Additionally, we have learned how to work in a business setting, communicating and coordinating with different companies, as well as different departments in the Guilford Mills facility, so that we can make our project the best that it can be.

U.S. Army Pine Bluff Arsenal | Launderable Protective Clothing Maddie Wilson, Owen Lindey, Gunikka Ahuja

Our Senior Design project is sponsored by Pine Bluff Arsenal (PBA), which has a 15 person production line for clothing and textile products at their facility established by the U.S. Army. One of the products the Pine Bluff facility produces is chemical protective and flame resistant clothing (coveralls and smocks) using PyrolonTM or similar material. The problem, however, is that PyrolonTM does not appear to be launderable and is only good for three to seven uses. Our team is tasked with recommending a launderable, flame resistant material(s) which can prevent hexachloroethane from making contact with skin and clothing.

To achieve this, our team has conducted various tests during the past eight months to recommend fabrics to our sponsor that perform the best overall and are better suited to manufacture a chemical protective and flame resistant garment. To prevent hexachloroethane from making contact with skin and clothing, we conducted a particle filtration test with the help of the Nonwovens Institute. We also did flammability and moisture testing at the Wilson College’s Textile Protection and Comfort Center to see what fabrics offered flame-resistant properties and how they performed for moisture management. Since the current suit is not launderable and is only good for three to seven uses, we did laundry testing of all our prototype fabrics to see if they could last at least 10 washes in order to have a more long lasting and sustainable suit. Another issue we came across in our project was static buildup. The shoes and the coveralls that the workers wear at Pine Bluff can lead to potential static charge buildup that can lead to a spark in their workspace. To prevent this, we also tested our fabrics for static charge. It has also been important to consider the tear resistance and effective strength of the fabrics to provide as much safety to the workers as possible. Our team conducted trapezoid and grab tests to analyze how the various fabrics performed for strength and tear. After we finish all our tests, we plan to recommend a final fabric that performs the best overall.

Cortland | Metal-Polymer Hybrid Textiles for Biomedical Applications Sarah Park, Garyn Levitan, Allison Stephan

Our Senior Design project is sponsored by Cortland Biomedical, a company that makes custom-built biomedical textile structures. Creating a medical structure that will be inserted into the body is a long process because of manufacturing, post-processing and sterilization. The textile structure and metal component of heart valves (knit) and stents (braid) are usually produced separately and then manually sewn together. To reduce the number of steps during manufacturing, the goal of this project is to knit and braid polyester and nitinol together to create a metal-polymer hybrid textile structure. This project intends to decrease the amount of time needed to create a composite structure and additional labor needed.

Throughout the project, our team has learned a lot about the product development process and the planning required. We began the process by researching what materials to use in the composite fabric and selected polyester and nitinol because of their strength, biocompatibility and versatility in the medical device field. Our team focused on three key measurables for our design and testing: tensile strength, diameter and thickness. Once the initial prototype designs were created for the knit and braid structures, the ratio of polyester and nitinol was varied to assess how the measurables change. During the prototyping phase, we were able to gain experience with knitting and braiding machines as well as physical testing machines to connect inclass learning with hands-on work. Once the prototypes were finished, we tested them according to the measurables and benchmarks to assess how they perform. Our team then took note of modifications or changes to be made that would improve the performance for Cortland Biomedical. We are all grateful for the opportunity to learn more about creating products, operating machinery and standardized testing.

Hanesbrands | Natural Dyes Bailey Bush, Rachel Argabright, Laura Potok Our team was tasked with finding a food or essential oil by product that would be a basis for dyeing cotton fabrics that would support sustainability both ecologically and socially. Our team did extensive research on the dyeing process including scouring, mordanting and dyeing processes. During our ideation phase, our team identified 103 unique natural dye materials and then, based on guidance from our sponsor, refined that list to focus teas, spices and seeds. During our prototyping phase, we scoured cotton swatches, used alum and salt as mortants and dyed 15 unique dye materials including black tea, hibiscus tea, matcha tea, elderberry tea, turmeric tea, avocado seeds, cranberry tea, blueberry tea, pomegranate tea, chamomile tea, green tea, dandelion root tea, orange and spice tea, schizandra berry tea, and red rooibos tea. Lastly, we evaluated the natural dye sources based on various categories such as dye strength, washfastness, colorfastness and lightfastness.

Our team has learned a lot about the dyeing and evaluation process. Through prototyping we learned how to prepare our samples for dyeing, including scouring and mordanting to determine which mordant worked best for our natural dyes. Through evaluation and testing of our naturally dyed materials we learned about standard American Association of Textile Chemists and Colorists testing methods as well as methods to assess sustainability. We have also learned about the chemistry behind the dyeing process including the fixation, migration and diffusion steps. Our team learned how the dye molecules bond with the cotton fibers to produce colored fabric. Our team was also able to assess how dye molecules interact with natural protein fibers such as wool and silk to compare to cotton. Finally, our team also learned how to create a plan that supports the multiple step dyeing process and the time required to complete each step. We also learned to be flexible and adapt to the schedules of the labs as well as use other outside resources to ensure that our project would be completed on time.

Hanesbrands | Wellness Finishes and Fibers Hannah Crow, Emma Glover, Delaney Joyce, Tiffany Jones

HanesBrands sponsored our project group to create a garment that targets a post-pandemic Gen-Z and incorporates wellness finishes and fibers. Through brainstorming and ideation we decided to pursue the concept of a weighted garment. We were first inspired by the wellness benefits weighted blankets provide through pressure therapy. Some of these benefits include stress and anxiety relief, comfort, security and improved sleep quality overall contributing to a calmer nervous system.

A wellness finish we decided to incorporate was aromatherapy. Lavender is one of the most popular essential oils used and promotes relaxation and can help treat stress, nausea and insomnia. Our team combined the concept of a weighted blanket and aromatherapy to create a weighted sweatshirt with a lavender finish. The crewneck will be a 60/40 cotton/ lyocell blend for added softness. The weighted portion on the interior body of the sweatshirt will be removable so the garment can be laundered and also worn without the added weight. The crewneck will be treated with a lavender essential oil finish to provide aromatherapy benefits and create the ultimate wellness garment. Throughout the past year, our group has gained insight into the real-world challenges of working in industry. Some of the challenges we have faced include time and project management, project stop-gates, prototyping design, materials sourcing and balancing leadership. We have had the amazing opportunity to work with industry partners, college professors and researchers, and most importantly, the knitting, spinning, and dyeing and finishing lab managers to learn from their expertise to use in our project. The past year has taught us so much both individually and as a group. One of the biggest takeaways from our project has been learning the basis of applying our degrees to a real application for industry. Our team has not only worked well together both semesters, but also created a bond through project work and collaboration that will last long after graduation!

Teijin Aramid | Sustainable Aramids for Motorsports Ryan Cherry, Emily Petersen, Sean Fijen

The idea was simple: to figure out a way to use recycled aramid material in casual motorsport safety equipment as a way to branch out into textile sustainability and reach a new target market. The result was anything but simple: the first yarn created using a mechanically recycled aramid. This project presents a unique set of challenges, in both processing and material mechanical performance properties. The fiber recycling process results in ultra strong reclaimed fibers. However, they have a large distribution of length, complicating the spinning process.

After sorting through fibers, yarns were spun at the Zeis Textiles Extension spinning lab. The material utilizes a 80/20 blend of long staple length cotton and recycled Twaron. The yarn has improved tensile strength and cut resistance over pure cotton yarn, retaining some of the advantageous aramid properties while having a more comfortable hand. Currently, weaving options are being explored along with the use of short fiber compression molded composites in hard protection elements of sporting equipment. With a project aiming to produce Teijin’s first recycled aramid yarn, our team learned many lessons. Facing challenges with fiber processing, we learned how to pivot a project’s focus and goals to align with what would be more feasible. In addition to getting acquainted with ways of testing and characterizing new material, our team was able to develop in-house test methods to provide benchmark guidance when international test methods were unavailable. We learned how to go through the engineering design cycle: coming up with a final product application, designing a material that would meet that criteria and exploring alternative proposals to achieve the end goal. This project has been a tremendous opportunity for us to not only design and test textile material but also learn how to overcome the challenges associated with advancing sustainability within the wider world of textiles.

Gildan | Sock Durability Indicator Ruiying Zhu, Cecilia Huynh, Dane Hunt, Derek Summers

The goal of the Sock Durability Indicator project is to enhance Gildan’s data analysis of sock abrasion testing by minimizing the variability within the test method. Reducing the variability by altering the current standard test method’s parameters for optimum consistency will lead to reliable conclusions as to which fiber compositions and knit structures are more durable than others. Through this project, the team gained new technical skills such as standard textile testing methodology, data analysis and image analysis. The team also gained valuable industry experience and business soft skills by collaborating with a worldwide textile industry leader, Gildan, to identify and solve a common industry issue.

The project started with an ideation phase to brainstorm possible parameters that might influence sock durability and test data collection methods after observing the current testing standard in action. Research was completed to dive deeper into the science behind wear and abrasion. Next, the team constructed a measurable table, prioritizing a decrease in data variability, and decided on four potential modifications that could result in more consistent results from the test. The team worked collaboratively with Gildan to meet their testing requirements for proper execution and setup of the test. A design of experiments (DOE) was then developed for all relevant parameters and their possible options to determine which combination of parameters provides the most reliable results with the lowest coefficient of variation. ImageJ software was a leading option to analyze the pictures collected from the abrasion tests. Roughness calculations and fractal geometry were applied to the images in order to deeply analyze the details of the testing region. Other features of ImageJ were investigated to potentially measure the tension of the socks.

ATHify | Thermotherapy Activewear Kayla Wyatt, Emily Odykirk, Jessica Schwendeman The goal of our Thermotherapy Activewear Senior Design project was to enable athletes of all types to use heat therapy for muscle recovery in their daily lives. Current heat therapy requires bulky products that hinder movement, making treatment a burden. Our collaboration with ATHify aimed to prove the concept that a streamlined and discrete e-textile legging was a feasible concept for the future of heat therapy. The design of our product consisted of multiple sections: a heating element, power source, the legging and the integration of all components.

Throughout our ideation and design process, we explored the range of heated garments currently on the market and how the heated elements were constructed, as there is limited research available in this emerging industry. During that process, our team understood that we were tasked with taking heated apparel to the next level by pushing it to the controlled therapeutic level and covering a greater area compared to garments designed for warmth alone. Over the last two semesters, we have gained an immense amount of knowledge and transferable skills. On the technical side, one of our most important areas of exploration was the mechanics of resistive heating, as that was the best option for our application. We learned how to have a textile material (resistive heating braided elastic) emit heat and how to optimize its ability for consistent spread over a designated area. To get a basic understanding of what function the heat therapy leggings needed to serve, research on the body’s physiology was conducted. Because we were exploring a new area in development, we utilized the valuable knowledge of faculty in the college and industry. Our project led to an abundance of cross-collaboration with industry, reinforcing the value of asking lots of questions and keeping future manufacturability in mind.

Textile Engineering | Undergraduate Degree Facts Tailor a Program to Fit Your Educational Goals • Three Curriculum Tracks - Information Systems Engineering - Design systems to make better decisions that improve people’s lives. - Chemical Processing - Develop chemical processes to make the world a better place. - Product Engineering - Design new innovative products to solve the world’s challenges. • Dual Degree Options - TE/BME (Biomedical Engineering) - TE/CHE (Chemical Engineering) - TE/MSE (Materials Science Engineering) - TE/CSC (Computer Science) - TE/ISE (Industrial and Systems Engineering) - TE/PCC (Polymer and Color Chemistry) • Minors in a Variety of Disciplines • Accelerated Bachelor’s Master’s (ABM) Program - Five-year program that enables concurrent pursuit of a B.S. and M.S. in TE for academically strong students. The Advantages are Impressive • Average starting salary: $58,210 ($45k - $80k) in 2017. • 98% placement in 2015, 96% placement in 2014, 97% placement in 2013 graduating classes. • Small class sizes with 1:30 professor-to-student ratio. • Joint program between the Wilson College of Textiles and the College of Engineering (COE). • More than 50% of TE students receive scholarships. • Lifelong access to Wilson College’s Career Center. • Undergraduate research with renowned and diverse faculty. • Classrooms and labs rival those in industry. • The top ABET-accredited textile engineering program in the United States. • Only NC State engineering program that trains students in Lean Six Sigma Quality process improvement methodology. • Exciting summer internship opportunities: Nike, PGI, HanesBrands Inc., The North Face, Target, Patagonia, Uni-fi, Tempur Sealy, Limited Brands, Technimark, Deutsche Bank, Eastman Chemical Company, Natick, SAS and PGI Aachen University (Germany).

TE Students Succeed • Sam Jasper becomes the second TE awarded national Astronaut Scholarship Foundation Award in 2016. • Won overall Engineering Senior Design (2014, 2015). • Joseph Moo-Young becomes the third TE to win the prestigious COE faculty rising senior scholar in 2014. • Park, Centennial, Goodnight, Shelton Leadership and Caldwell Scholarship Recipients. • Emily McGuinness NSF Graduate Fellowship in 2017. Senior Design Projects Technology, Manufactoring, Math and Sciences

Textile Technology General

Supply Chain Operations

Medical Textiles

Technical Textiles

Senior Design I & II

• Rigorous, open-ended problem solving. • Industry and government sponsored projects: Nike, HanesBrands Inc., U.S. Army, Under Armour, Patagonia, Firestone, VF, Gildan, Willow Wood, Eastman, NASA, Saab Baracuda, Monterey Mills, Cotton Inc. and Gryppers. • Biometric feedback shirt, Energy harvesting textiles, Realistic bite sleeve for canine training, 3-D fabric for prosthetics, Advanced flame retardant apparel, Wading/ submersion fabric durability, Quick to market textiles, Advanced camouflage surface treatments, Cooling vest for firefighters and Textile composites for structural beams.

Textile Technology | Undergraduate Degree Facts Tailor a Program to Fit Your Educational Goals • One General Curriculum Track - Textile Technology - Allows students the flexibility of designing their own interests or transferring from other programs or community colleges. • Three Specialized Curriculum Tracks - Supply Chain Operations - Prepares students to manage the entire supply chain from raw materials to retail. - Medical Textiles - Allows students to gain experience in the design and production methods for textile medical applications. - Technical Textiles - Enables students to develop expertise and analytical skills needed to design and manufacture textiles for nonwovens and high-tech applications. • Dual Degree Options - French Language • Minors in a Variety of Disciplines - Environmental Sciences - Business Administration - Statistics - Arts Entrepreneurship - Sports Science • Accelerated Bachelor’s Master’s (ABM) Program - Five-year program that enables concurrent pursuit of a B.S. in TT and M.S. in TE for academically strong students academically strong students. The Advantages are Impressive • Average starting salary: $58,500 ($45k - $93k*) in 2017. • 96% placement in 2015, 97% placement in 2014, 93% placement in 2013 graduating classes. • Small class sizes with < 1:25 professor-to-student ratio. • Access to largest college-based scholarship program. • Lifelong access to Wilson College’s Career Center. • Undergraduate research with renowned and diverse faculty. • Classrooms and labs rival those in industry. • Exciting summer internship opportunities: Ralph Lauren, HanesBrands Inc., Smithsonian Institute, Under Armour, Unifi, Glen Raven, American & Efird, Limited Brands, Spanx Inc., Kohls, Shaw Industries, Cotton Inc., Eastman Chemical, International Textile Group, Michael Kors, Milliken, PGI, Spanx and Precision Fabrics.

TT Students Succeed • Courtney Bolin interned at The Smithsonian Institute. • Centennial Scholarship Recipients. Senior Design Project Fundamental Engineering, Math and Sciences

Chemical Processing

Product Engineering

Information Systems Engineering

Senior Design I & II

• Rigorous open-ended problem solving. • Industry and government sponsored projects: Nike, HanesBrands Inc., U.S. Army, Under Armour, Patagonia, Firestone, VF, Gildan, Willow Wood, Eastman, NASA, Saab Baracuda, Monterey Mills, Cotton Inc. and Gryppers. • Industry and government sponsored projects: Nike, HanesBrands Inc., US Army, Under Armour, Patagonia, Firestone, VF, Gildan, Willow Wood, Eastman, NASA, Saab Baracuda, Monterey Mills, Cotton Inc. and Gryppers. • Biometric feedback shirt, Energy harvesting textiles, Realistic bite sleeve for canine training, 3-D fabric for prosthetics, Advanced flame retardant apparel, Wading/ submersion fabric durability, Quick to market textiles, Advanced camouflage surface treatments, Cooling vest for firefighters and Textile composites for structural beams.