What is a Nonwoven Fabric?...• Market size: $7.9B –6.1% growth rate since 2011, slowing to 5.1%...
Transcript of What is a Nonwoven Fabric?...• Market size: $7.9B –6.1% growth rate since 2011, slowing to 5.1%...
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Copyright - NWI, NC State University - 1991-2019
Important Trends Impacting Nonwoven Technology in Industrial Fabrics
Dave NelsonDirector, Industry Engagement
The Nonwovens InstituteNC State University
Copyright - NWI, NC State University - 1991-2019
What is a Nonwoven Fabric?
Copyright - NWI, NC State University - 1991-2019
What Is a “Nonwoven Fabric”?
“A fabric made from a web of fiber”
Assembly of loose fibers Fiber held together by
bonding/interlocking
Spunbond /Thermal bonded Nonwoven
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What Is a “Nonwoven Fabric”?
ISO 9092 (2011) “A nonwoven is a structure of fibers, continuous filaments, or
chopped yarns of any nature of origin that have been formed into a web by any means, and bonded together by any means with the exception of weaving or knitting, and wet milling.”
ISO 9092 (2019) “ An engineered fibrous assembly, primarily planar, which has been
given a designed level of structural integrity by physical and/or chemical means, excluding weaving, knitting or papermaking”
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What Is Not a “Nonwoven Fabric”?
Knit
Woven
Paper
Film
(www.cogentemr.com) (Erksen et al 2005) 5
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Unique Nonwoven Aspects
Nonwovens Variable fiber orientation
Structure non-uniformity
Diverse web bonding methods: mechanical, thermal, chemical
Woven Clearly Defined Geometry,
x, y orientation Strong x, y direction, weak bias direction
Bonding: Friction, interweaving, weave crimp
Wetlay Thermal bond
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Nonwoven Product & Applications
Nonwoven applications Nonwovens are the fabrics that you don’t see,
but are there where you need them;
They are the fabrics that you don’t recognize,
but are performing in ways that others can’t
Wide ranges of nonwoven products in wide ranges of applications
Possibility to produced highly engineered and customized product
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Today’s Message
The nonwovens market is
a successful, growing,
continuously evolving, dynamic
and diverse industry!
A $15.5B Industry in North America2018 Nonwoven Material/Rolled Goods at the Producer Level
Copyright - NWI, NC State University - 1991-2019
Nonwoven Market Segments by Applications (243 product categories)
Short-life (Disposable) Absorbent Hygiene
Wipes
Filtration
Medical/Surgical
Other Disposable Applications
Long-life (Durable) Building Construction
Home and Office Furnishings
Vehicle Construction
Geosynthetics
Apparel
Other Durable Applications
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115 distinct product
categories
128 distinct product
categories
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4%
6%
8%
0% 2% 4% 6% 8%
Robust Global ProductionProduction Growth in Tonnes, Historical and Forecast Average Annual Growth Rates
Source: Worldwide Nonwovens Industry Outlook, INDA/EDANA, 2015
HistoricalGrowth
ForecastGrowth
Historical Growth5.7% 2008-2018
903k per Year
Forecast Growth4.8% 2019-2023
776k per Year
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0%
2%
4%
6%
8%
0% 2% 4% 6% 8%
Strong and Steady Growth in North AmericaProduction Growth in Tonnes, Historical and Forecast Average Annual Growth Rates
Source: INDA, April 2019
Historical2013-2018CAGR
Forecast2019-2023
CAGR
Historical Growth5.1% 2013-2018
185k per YearForecast Growth4.3% 2019-2023
198k per Year
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North American Nonwoven Market
Durable35%
Disposable65%
North American Nonwoven MarketTonnage Consumption, 2013
$12.1 Billion Sales of materials at producer level
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Distribution of North American ProductionNorth America Production by End Use in Tonnes, 2018
Source: INDA North American Nonwovens Supply Report 2018, April 2019
Green Shades RepresentDurable End-Use Markets
52%
Blue Shades RepresentDisposable End-Use Markets
48%
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North America Investments Exceed GDP North America Capacity by Process, 1990 to 2018, in Thousands of Tonnes
28 yearsNonwovens 4.6%U.S. GDP 2.4%
Investments Have Been
and Will Continue To Be
Made in North America
Source: INDA North American Nonwovens Supply Report 2018, April 2019
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Diversity of Processes…North America Capacity Additions by Web-Forming Process
Number of Lines and Thousand of Tonnes, 2016–2018 (69 new lines, 613,450 tonnes)
Source: INDA, June 2019
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North American Nonwovens Market
Growth Drivers:• Demographics• Strength of global
economy• Innovation• Material substitution• Regulation
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North American Nonwovens Market
Durables Growing > 2X Disposables
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Nonwovens In Filtration
Air Filtration Industrial/Manufacturing
Transportation
Commercial Air Systems
Residential Locations
Personal Protection
Vacuum Cleaner
Liquid Filtration Transportation
(oil/hydraulic/lubrication/fuel)
Industrial/Manufacturing
Water
Food and Beverage Processing
Largest NW Market behind Hygiene and Wipes includes30 Major Market Segments
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Market Outlook for Filtration
>$32B End Use Sales
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Market Outlook for Filtration
• Primary Growth Drivers: The economy …. 2.2% annually since
2011 Consumer awareness and sensitivity Government legislation and regulation Passenger car and light truck production
(+6% since 2011) New residential starts (+14% since 2011) Residential repair and remodel Private non-residential construction Public non-residential construction
• Secondary Drivers: Filter efficiency improvements Increasing share of nonwovens in filter
media Nanofibers (?) Sustainability
Why Nonwovens?
• Can be specifically engineered for the exact filtration performance desired
• Can be specifically engineered for the physical and chemical properties desired
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Industrial/Manufacturing
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Dust collections systems (bag filters) and air intake systems (cartridge filters)
Growth Drivers:• Energy Usage• Emissions Reduction• Technology Advances• Cost Reduction
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Engine Filtration
• Air induction, engine oil and inline fuel filtration • Market size: $7.9B – 6.1% growth rate since 2011, slowing to
5.1% thru 2021• Materials:
Lighter weight polymeric materials taking the place of cellulosic wetlaid Smaller, more efficient filters
• Requirements: Higher efficiency, longer life, reduced pressure differential, etc., without,
providing a ˝larger˝ filter:
Tighter tolerances and on-board engine control to protect instruments such as mass-air-flow sensors (MAF):
• Filters must contribute to decreasing engine wear
To remove smaller and smaller particles:
• Multi-stage filter systems - the rule and not the exception.
The diversity of microfiber/meltblown/spunbonding technology will contribute.
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Cabin Air Filtration
• Air Contaminants in the automobile include Exhaust fumes
Dust
Odors
Volatiles from interior components (carpeting, moldings)
• Filters are included as part of the HVAC system
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Cabin Air Filtration
• More than 1/3rd of North American cars had cabin filters in 2014, now almost 100% -fastest growing segment for transportation
• Filters are designed to be replaced during routine maintenance• Meltblown or composite nonwovens are used as the filtration media with electrostatic
charge added to improve their capture efficiency• Required properties:
Accommodate space restraints (as small as 0.5 m2) Sustain a low pressure drop High collection efficiencies of fine particles (<3 m) Blockage-proof Perform in high humidity Rigid design Non-toxic binders Ideally, remove odor and be 100% recyclable
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Commercial HVAC
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Low, Medium and High Efficiency Segments – High Efficiency (HEPA and ULPA growing the fastest -8.6%)
Growth Drivers:• Energy Usage• Sick Building Syndrome/Health• Technology Advances
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Residential Air Filtration
Residential HVAC
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Grow Drivers:• Concern over indoor air quality –
demanding “real” filtration vs. protecting the furnace
• Portable room air purifiers• Consumer IQ• Technology – media and product design
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Personal Protection
Includes: Face Masks (not regulated) and Respirators (regulated)
Grow Drivers:• Threat of infections and pandemics• Worker and consumer safety demand
and regulation• “Fashion”• Technology – fit, comfort, specific
uses, etc.
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Vacuum Cleaner Filters
Bag vs. Bagless
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Liquid Filtration
Major Segments: Transportation (fuel, oil, lubrication, hydraulic)
Industrial/Manufacturing (high tech, hydraulics, hydrocarbon processing, industrial processes
Water (industrial processes, swimming pools/spa, water treatment)
Food and Beverage Processing
Healthcare (biotech/pharma, blood)
Growth Drivers: The economy
Consumer awareness and sensitivity
Legislation and regulation
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Liquid Filtration
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Technology Drivers:• Filter Efficiency Demands• Innovative Nonwoven Materials• Selective Separation• Sustainability• Composites• Testing• Product Design
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Nanofiber and Composite Media Technology
Product InnovationMaterial / Technology Development
Images Courtesy of Berry Global and M. Faccini, C. Vaquero, and D. Amantia
Spunbond
Nanofiber
Meltblown
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Nanofiber and Composite Media Technology
Product InnovationMaterial / Technology Development
Images Courtesy of Cummins Filtration
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Nonwovens In Transportation
Automotive Passenger Vehicles
Light Trucks/SUV’s/Vans
Other Transportation Modes Heavy Trucks/Commercial Freight/Buses/RV’s
Air
Rail
Water
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Market Outlook for Transportation
• INDA has expanded “automotive” to “transportation”
• Strong recovery of automotive industry, plus higher growth rates for “other transportation” – now slowing
• Excellent opportunities for nonwovens replacing conventional materials – textiles, glass, paper, leather, etc.
• Primary Growth Drivers: The economy ….
Passenger car and light truck production
Corporate Average Fuel Economy (CAFE) regulation
• Secondary Drivers: Pent-up demand
Fuel efficient vehicles (light weight material substitution)
Increased vehicle size
Parts consolidation (composites)
Aging population/Driverless cars/Shared Rides/ownership?
Strong RV and leisure market
Changing filtration needs for vehicle of the future
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Automotive Nonwovens
Interior• Headliner
− Acoustic Control− Face Fabric− Insulation
• Dashboard Insulation− Acoustic Control− Insulation
• Carpet and Flooring• Seats• Interior Trim• Cabin Air Filtration• Air Bags
Engine/Exterior• Wheel Housing• Fire Retardancy• Hood insulation• Fluid Filtration• Engine Air Filtration• Heat Shields• Molded Bonnet Liners
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Nonwovens in Transportation
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Product InnovationMaterial / Technology Development
Images Courtesy of Freudenberg
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Product InnovationMaterial / Technology Development
Images Courtesy of Autoneum
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Acoustic Insulation
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Filtration
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Aerospace, Rail, Ship Building
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Nonwovens In Construction
End Uses: Roofing (Residential and Non-
residential)
Underlayment (Housewrap, Roof Underlayment, Other)
Other Building Construction (Product Facing Materials, Insulation Panels/Boards, Other)
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Market Outlook for Construction
Growth Drivers: New residential starts
Existing home sales
Repair and remodel
Private and public non-residential
Secondary Drivers: Pent-Up Demand
Energy Codes and Other Regulations
Nonwoven Material Share
Product Innovation
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Nonwovens In Home and Office Furnishings
End Uses: Flooring (carpet, underlayment, entrance
and walk-off mats) Upholstering Bedding (mattress, bed coverings and
linens) Other (window treatment, wall coverings,
acoustic, other padding)
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Market Outlook for Home and Office Furnishings
Growth Drivers: New residential starts
Existing home sales
Repair and remodel
Business spending
Secondary Drivers: Regulation – i.e. flammability
Style/Design - aesthetics
Capturing share from other materials
Product Innovation –functionality, weight, cost
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Nonwovens In Geosynthetics
End Uses: Civil Engineering (road, drainage,
containment, cure-in place pipe) Agriculture (crop covers, shading,
landscape fabrics, root and product bags
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Market Outlook for Geosynthetics
Growth Drivers: Public infrastructure
Private infrastructure
Regulatory
Secondary Drivers: Government spending
Nonwoven Material Share
Product Innovation
Sustainability – “organic” “green”
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Nonwovens in Apparel
End Uses: Thermal Insulation Artificial Leather Interlinings/Interfacings PPE (military, 1st responders,
police, safety) Shoe Materials Recreational Wear
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Market Outlook for Apparel
Growth Drivers: The economy
Demographics
Material substitution
Secondary Drivers: Apparel design
Regulatory
Manufacturing in NA
Product Innovation –aesthetics, cost, functionality
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Markets and Products for Safety Applications
• Filtration – Personal Protection Face Masks (non-regulated)
• 5.8% sales growth forecasted (2013-2018)
Respirators• 7.5% sales growth forecasted (2013-2018)
No recent “pandemics” i.e. Avian Flu, etc.
• Personal Protective Equipment – PPE (sales growth forecast – 7.2%)
Emergency Response, Chemical Biological Hazard Apparel
Agriculture, Paint, Food Processing Apparel
Cleanroom/Laboratory Apparel
Market Drivers: the economy, legislation and regulatory control
• Medical (sales growth forecast – 4-5% range)
Surgical Packs and Gowns
Other Apparel – masks, headcovers, shoe covers, bedding
Market Drivers: aging population, in home healthcare, infection prevention awareness
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Protective Apparel - PPE
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Medical Fabrics and Apparel
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Other Applications
End Use Comprises: Durable Graphics (art, maps, book covers)
Electronics • Battery separators
• Cable insulators
• Conductive/smart fabrics
Fabric Graphics
Fabric Structures
Industrials Felts (gaskets, seals, sound/vibration dampening)
Advanced Composites• Pre-preg
• Membranes
• Military
Main Drivers: The economy
New markets
New products
Secondary Drivers: Product innovation
Product substitution
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Why We Need Fine Fibers For Mechanical Filtration
B Maze, HV Tafreshi, Q Wang, & B Pourdeyhimi, J. Aerosol Sci., 38, 550 (2007)
SVF=1.7%; 10 nm< dp<150 nm
Copyright - NWI, NC State University - 1991-2019
Electrospinning
A New Old Technology Electrospinning
Co-axial Electrospinning
Emulsion Spinning
Melt Electrospinning
Sometimes it takes a LONG time to find the value of a new technology…
This technology was re-discovered only recently
Copyright - NWI, NC State University - 1991-2019
Electrospinning
Nozzle based Nozzle-less
Free liquid surface electrospinning of Polyvinyalcohol(Courtesy of David Lukas, Technical University of Liberec)
Rotating drum is dipped into a bath of liquid polymer. Thin layer of polymer is carried on the drum surface and exposed to a high voltage electric field.When the voltage exceeds the critical value Ec, a number of electrospinning jets are generated.
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2020
Fiber Diameter, nm
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Fre
qu
enc
y
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5
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Mean 1482 nmSD 872 nmMin 495 nm
0.2-C-20
Fiber Diameter, nm
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Fre
qu
en
cy
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10
20
30
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Mean 332 nmSD 253 nmMin 64 nm
0.012-A-2.5
Fiber Diameter, nm
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Fre
qu
en
cy
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2
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Mean 499 nmSD 368 nmMin 10 nm
0.002-B-0.5
Meltblowing:Hills High Density Dies
Copyright - NWI, NC State University - 1991-2019
The NWI ProcessFibrillating Bicomponent Fibers
• The islands in the sea or multilobal fibers are sheared and subjected to high pressure water jets to simultaneously fibrillate and entangle and consolidate the microfilaments.
50/50 Sea-Island Ratio
Number of Islands
7 37 240
600
1200
Dia
mte
r (
m)
7.00
2.00
0.87
0.340.220.15
US Patent 7,883,772US Patent 7,981,336 US Patent 7,981,226US Patent 7,438,777
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Denier Per Filament0.0001 0.001 0.01 0.1 1 10 100 1000
Sp
ecif
ic S
urf
ace,
m2 /g
0.01
0.1
1
10
100
Round
4DG
Winged
Diameter (Microns)0.1 1 10 100 1000
The NWI ProcessSuper Surface Area Fibers…
Photos courtesy of Allasso Industries. Inc.
US Patent 8,129,019 B2, March 6, 2012US Patent 8,410,006 B2, April 2, 2013
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And, Fibers Below 50 nm ??UIC & NWI – Disruptive Tech.
Supersonic electrically-assisted blowing and resulting nanofibers. (a) Schematic of the electrically-assisted solution blowing setup. (b) Two-stage stretching of polymer jet and crystal sheet alignment and packing.
Patent Pending
Copyright - NWI, NC State University - 1991-2019
Nonwovens Will Continue to Grow
• Trends that drive the growth Population growth, urbanization, increase in prosperity, scarcity of natural resources, health
awareness and sustainability
• China and developing nations are the fastest growing markets for nonwovens and especially filtration
• New fibers, new process technologies, new products are needed to meet market needs Industrial fabrics of the future requires new materials, processes and integration systems that have
not been developed yet…
Copyright - NWI, NC State University - 1991-2019
Nonwovens Will Dominate Many Markets
• The Nonwovens Industry is High volume Highly innovative Growing Mostly focused on melt spinning Highly automated
• The main opportunities are in New resins
• Polyamides• PBT• PLA• Others – water soluble?
New additives• Nucleating agents, etc., electret• Surface energy• Alcohol repellency
New chemistries Composites
• The segments to penetrate Filtration Transportation Durables/Apparel Geosynthetics Medical/Hygiene
• Drivers Multi-functionality Sustainability Lower weight Lower energy Higher differentiation Low labor component
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The Nonwovens InstituteEstablished 1991 as a NSF State I/UCRC
The Nonwovens Institute is a university-wide unit that works with the faculty in the participating colleges and partner universities and member companies to support the various industrial sectors that it represents… and train future leaders for the industry…
Nonwovens Institute
Fiber & Polymer Science
Fiber & Polymer ScienceChemical Engineering
Paper Science & Engineering
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Industrial Needs & Challenges
• Balancing long-term & short term research objectives is the major issue faced by the industry. We have to do both…
• Problem driven industrial needs are often short term and applied… looking for a product in a structured manner involving a stage-gate process. NWI carries out this on a one-to-one basis.
• Longer term basic and fundamental research is also critical for creating an innovation pipeline. NWI has a shared research platform for its members
Create KnowledgeCreate Knowledge Add ValueAdd Value Transfer KnowledgeTransfer Knowledge
Copyright - NWI, NC State University - 1991-2019
What Does NWI Actually Do?Vertical Integration is Key – TRL 1-8
Knowledge Creation
Funded by NWI membership dues
PhD Research
Graduate Certificate
Short Courses
In-plant Training
50+ PhD Students
Faculty
Meet twice/year
Project monitoring
Typically no IP, but Bylaws define IP rights
Funded by NWI membership dues
PhD Research
Graduate Certificate
Short Courses
In-plant Training
50+ PhD Students
Faculty
Meet twice/year
Project monitoring
Typically no IP, but Bylaws define IP rights
Knowledge Transfer
Nonwoven Products and Processes
Manufacturing Process Fundamentals
Spunbonding & Meltblowing
Fundamentals
Bonding Fundamentals
Characterization Methods
Product Development
Nonwoven Products and Processes
Manufacturing Process Fundamentals
Spunbonding & Meltblowing
Fundamentals
Bonding Fundamentals
Characterization Methods
Product Development
Testing & Fabrication
Funded by Sponsor
No student/faculty involvement
Research Staff only
Confidential
Sponsor present at trial
Sponsor defines protocol
Simple Agreement with no IP terms
Enabler for innovation
Funded by Sponsor
No student/faculty involvement
Research Staff only
Confidential
Sponsor present at trial
Sponsor defines protocol
Simple Agreement with no IP terms
Enabler for innovation
New Product Development
Funded by Sponsor
No student involvement
Research scientists
Meet monthly
Reporting requirement
Project monitoring
Option to License IP generated
Assistance with commercialization
Funded by Sponsor
No student involvement
Research scientists
Meet monthly
Reporting requirement
Project monitoring
Option to License IP generated
Assistance with commercialization
Incubation
LINC, LLC
Affiliated entity of NC State
Help commercialize technologies
developed at NWI
Manufacture on a limited basis products
Identify companies who can produce the
products
Help build new facilities
Transfer technology to client
Affiliated entity of NC State
Help commercialize technologies
developed at NWI
Manufacture on a limited basis products
Identify companies who can produce the
products
Help build new facilities
Transfer technology to client
TRL 1-8TRL 1-8
LINC is a non-profit affiliated entity of NC State…
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NWI’s Mission
Knowledge creation and diffusion by conducting and sharing relevant basic research with stakeholders and policy makers and Creating a shared scientific basis for joint resolution of complex materials and manufacturing issues,
Training the next generation of engineers/scientists as future leaders for the industries we represent,
Technical and expert assistance in new product development to bring about new opportunities for the industry,
Technology transfer and assistance with commercialization through incubation of new products,
Be the “go-to” information resource for communications and research, development and education tools, and Coordinating professional development opportunities.
Forecasting technology and market needs through market intelligence to foster new opportunities for stakeholders.
Diagnostic and testing and pilot production services by creating testbeds and make these available at reasonable fees,
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Thank You !!
Any Questions?
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