• • Continuous melt extrusion enables fabrication of theoretically infinite-length micro-grooved fibers (MGFs) with feature sizes down to a few microns, overcoming batch-processing limitations of lithography or laser-writing.
• • MGF fabric achieves an evaporation rate approximately 4 times higher than smooth fiber (SMF) fabric and 2 times higher than commercial Cool-max fabric, demonstrating superior moisture management for activewear.
• • By applying twisting at the die exit, left- and right-handed micro-grooves with tunable helix angles are produced, enabling directional liquid transport on predefined paths.
• • The process uses high-density polyethylene (HDPE) and is solvent-free, low-cost, and scalable, aligning with environmentally-friendly manufacturing requirements.