Fibre Blending Strategies in Nonwoven Fabrics: Advances toward High Performance and Sustainable Applications

Abstract

Nonwoven fabrics have become integral to numerous industries due to their lightweight, versatile and cost-effective nature. It’s unlike traditional woven or knitted textiles, are manufactured by bonding or interlocking fibres through mechanical, thermal or chemical processes without converting them into yarns. A critical aspect of nonwoven production is fibre mixing and blending, which enables the enhancement of material properties such as tensile strength, absorbency, flexibility and functionality. The rising global demand for lightweight, high-performance and eco-friendly materials has driven innovation in nonwoven blending technologies. This review explores the strategic blending of synthetic, natural, regenerated and speciality fibres to meet diverse application needs in sectors like hygiene, medical, filtration, and geotextiles. This review compiles and synthesises recent research that emphasises the objectives of fibre blending, including performance optimisation, cost reduction and functionalization. A diverse range of fibre types—natural, synthetic, regenerated and speciality is used in nonwoven fabric production. The selection is based on intended end-use performance, processing compatibility, cost and environmental impact. This paper also highlights challenges such as achieving fibre compatibility and uniform distribution, as well as the growing importance of sustainable and biodegradable fibre options. Advances in digital control, nanofibres integration and bio-based material use are expanding the potential of nonwoven fabrics. Overall, fibre blending remains a cornerstone in engineering nonwovens for modern performance and sustainability requirements. The advancement of nonwoven fabric technology has opened new frontiers in material science, particularly through the strategic use of fibre mixing and blending. Continued interdisciplinary collaboration and technological investment will unlock the full potential of blended nonwoven materials in global industries. This review provides a timely resource for advancing multifunctional and eco-friendly nonwoven materials through strategic fibre blending.