Award Abstract # 2236100
NSF Convergence Accelerator Track I: Sustainable Materials for Global Challenges: Recycled Textile and Apparel Manufacturing Ecosystems (RETAME)

NSF Org: ITE
Innovation and Technology Ecosystems
Recipient: UNIVERSITY OF DELAWARE
Initial Amendment Date: December 14, 2022
Latest Amendment Date: December 14, 2022
Award Number: 2236100
Award Instrument: Standard Grant
Program Manager: Richard Farnsworth
rlfarnsw@nsf.gov
 (703)292-5029
ITE
 Innovation and Technology Ecosystems
TIP
 Directorate for Technology, Innovation, and Partnerships
Start Date: December 15, 2022
End Date: November 30, 2024 (Estimated)
Total Intended Award Amount: $745,310.00
Total Awarded Amount to Date: $745,310.00
Funds Obligated to Date: FY 2023 = $745,310.00
History of Investigator:
  • Kelly Cobb (Principal Investigator)
    kcobb@udel.edu
  • Abigail Clarke-Sather (Co-Principal Investigator)
  • Huantian Cao (Co-Principal Investigator)
  • Kedron Thomas (Co-Principal Investigator)
Recipient Sponsored Research Office: University of Delaware
550 S COLLEGE AVE
NEWARK
DE  US  19713-1324
(302)831-2136
Sponsor Congressional District: 00
Primary Place of Performance: University of Delaware
220 HULLIHEN HALL
NEWARK
DE  US  19716-0099
Primary Place of Performance
Congressional District:
00
Unique Entity Identifier (UEI): T72NHKM259N3
Parent UEI:
NSF Program(s): Convergence Accelerator Resrch
Primary Program Source: 01002324DB NSF RESEARCH & RELATED ACTIVIT
Program Reference Code(s):
Program Element Code(s): 131Y00
Award Agency Code: 4900
Fund Agency Code: 4900
Assistance Listing Number(s): 47.084

ABSTRACT

Clothing is a basic human need, yet the way we clothe ourselves today is fundamentally unsustainable. The fashion industry is one of the largest contributors to global carbon emissions and water contamination, and the industry yields more than 100 million tons of textile waste each year. The Recycled Textile and Apparel Manufacturing Ecosystems (RETAME) project brings together academic researchers from engineering, design, and the social sciences, industry partners, and the non-profit organization, Goodwill Industries, to build a sustainable recycled materials model for the textile and apparel industry. By converting post-consumer fashion waste into new products, RETAME keeps clothing out of landfills, generates revenue from existing waste streams, and reduces the need for virgin materials. The project focuses on the development of 1) novel mechanical recycling technologies, 2) product prototypes made from recycled fibers and textile pieces, and 3) educational and skills training programs for job seekers and students, especially those from underrepresented and disadvantaged groups. The project will yield a model recycling ecosystem to grow the Delaware Valley regional economy and improve the environmental sustainability of our clothing. Team members will document and evaluate the project at every stage to develop best practices for implementing the model in other regions.

The overarching goal of RETAME is to gather proof of concept for a sustainable recycled materials model for the textile and apparel industry that can be replicated in regions across the United States and around the world. RETAME accomplishes this goal by leveraging regional expertise and locally available waste materials. Team members are experts in sustainable textile design; engineering design; textile science; cultural anthropology; textile manufacturing and recycling; educational curriculum development and implementation; diversity, equity, and inclusion; and non-profit management of used clothing collection and retail.

The project involves the following methods and approaches: 1) the recruitment of collaborators in areas of waste and recycling policy, waste management, consumer science and behavioral economics, supply chain and logistics management, regional economic development, and environmental justice; 2) the design and testing of an aggregation, sorting, and mechanical textile recycling supply and production chain in the Delaware Valley region in partnership with Goodwill Industries; 3) the advancement and piloting of mechanical recycling technology and equipment for converting post-consumer clothing waste into reusable fibers; 4) the development of next-generation recycled textile composite prototypes; 5) analysis of the materials properties of recycled textile samples and the collection of initial data on the life cycle impact of relevant processes and products; and 6) ethnographic research and analysis of team-building, knowledge sharing, and convergence research strategies to yield results that will support the ecosystem model?s transfer and application to other regions.

Broad-based convergence research is necessary to build robust partnerships that can generate circular, sustainable ways of clothing ourselves. RETAME leads this effort by modeling the development of post-consumer fashion waste recycling and manufacturing systems that also support sustainable, regional economic development.

This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

PUBLICATIONS PRODUCED AS A RESULT OF THIS RESEARCH

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Teixeira França Alves, Paulo Henrique and Bahr, Gracie and Clarke-Sather, Abigail and Maurer-Jones, Melissa "Combining Flexible and Sustainable Design Principles for Evaluating Designs: Textile Recycling Application" Journal of Manufacturing Science and Engineering , 2023 https://doi.org/10.1115/1.4063993 Citation Details
Cobb, Kelly and Thomas, Kedron and Clarke-Sather, Abigail and Cao, Huantian "ReSpool: An Approach to Scaling a Circular System for Textile Recycling and Sustainable TextileInnovation Through Convergence Research." , 2024 https://doi.org/10.31274/itaa.18909 Citation Details
Durrani, Hira and Clarke-Sather, Abigail R and Alves, Paulo HTF "Prospective Life Cycle Assessment of Nonwoven Mat Manufacturing: Comparing Pre-Consumer Wood Waste Fibers to Post-Consumer Recycled Apparel Fibers" , v.88391 , 2023 Citation Details
Ludwig, Kendall and Yatvitskiy, Michelle and Cobb, Kelly and Cao, Huantian "The Respool Fiber Research (RFR) model: A protocol for the evaluation of mechanically recycled materials towards second life product applications." , 2025 https://doi.org/10.31274/itaa.18827 Citation Details
Teixeira França Alves, Paulo Henrique and Clarke-Sather, Abigail and Carlson, Sam and Martini, Angela "Theoretical Method for Characterizing Textile Failure Mechanics in Mechanical Recycling With Carded Drums" , 2023 https://doi.org/10.1115/MSEC2023-104361 Citation Details
Thomas, Kedron and ClarkeSather, Abigail_R and Cobb, Kelly and Cao, Huantian "ReSpool : Scaling a circular supply chain for recycled textiles" Journal of Advanced Manufacturing and Processing , 2025 https://doi.org/10.1002/amp2.70000 Citation Details
Thomas, Kedron and Durrani, Hira and Brady, Julia and Ludwig, Kendall and Yatvitskiy, Michelle and Clarke-Sather, Abigail R and Cao, Huantian and Cobb, Kelly "Fundamental Challenges and Opportunities for Textile Circularity" Sustainability , v.16 , 2024 https://doi.org/10.3390/su162411117 Citation Details
Yatvitskiy, Michelle and Abayode, Diadem and Cobb, Kelly and Thomas, Kedron and Haddad, Nicole "Reviving Fashion: Weaving Life Back into Discarded Textile Waste" , 2024 https://doi.org/10.31274/itaa.18920 Citation Details
Yatvitskiy, Michelle and Ludwig, Kendall and Gupman, Sophia and Cobb, Kelly and Cao, Huantian and Clarke-Sather, Abigail "Innovative Methods for Secondary Material Development in Mechanical Textile Recycling" , 2024 https://doi.org/10.31274/itaa.18903 Citation Details

PROJECT OUTCOMES REPORT

Disclaimer

This Project Outcomes Report for the General Public is displayed verbatim as submitted by the Principal Investigator (PI) for this award. Any opinions, findings, and conclusions or recommendations expressed in this Report are those of the PI and do not necessarily reflect the views of the National Science Foundation; NSF has not approved or endorsed its content.

ReSpool: Transforming Fashion Waste into Regional Textile Innovation

 

From 2023 to 2025, the ReSpool project brought together engineers, designers, scientists, and community partners to tackle one of the fashion industry’s most pressing challenges: textile waste. The ReSpool team developed new technologies and systems that transform discarded clothing into high-quality recycled textile materials—building a regional model for circular textile innovation. ReSpool's core innovation lies in its waste-led approach—designing processes and products based on what is already available in the waste stream. The team built a prototype Fiber Shredder, a mechanical recycling device that converts discarded apparel into reusable fibers, now refined and tested at lab scale,. In parallel, the team developed machines to speed up the removal of buttons and zippers, reducing labor costs and material contamination. ReSpool fibers, produced from cotton, polyester, rayon, and wool garments, were turned into yarns and nonwoven fabrics using thermal bonding and needle punching. Testing showed that yarns made with up to 85% recycled fibers maintained strong performance, while nonwoven fabrics made from higher percentages of recycled fibers were more breathable, making them suitable for applications such as weed-suppressing mats for environmental restoration.

 Building a Regional Network. ReSpool established strong regional partnerships in the Delaware Valley and the Upper Midwest, working with nonprofit leaders like Goodwill Industries, small textile brands, and manufacturers.  ReSpool also engaged in 21 interviews and extensive ethnographic research to understand the challenges and needs of community members, consumers, and industry stakeholders. These insights directly shaped future technical decisions, like investing in safe chemical separation for polyester and addressing risks of microplastic pollution during mechanical recycling.

A Model for Circular Systems. Beyond technical development, the team’s design thinking approach supported open communication across disciplines, allowing for deep collaboration between academic researchers and industry practitioners. Findings from qualitative team interviews helped clarify goals and improved collaboration throughout the project. This transparency and reflexive practice are now being developed into educational modules for use in design programs and industry training, supporting the spread of circular practices across the textile field.

The broader impacts of ReSpool are substantial:

 

  • Environmental: Diverts large volumes of post-consumer textile waste from landfills and gives new life to used clothing through high-value applications.
  •  Economic: Supports green job creation through workforce training with Goodwill and partnerships with women- and minority-owned businesses.
  •  Educational: Trains the next generation of sustainable designers and engineers—supporting 5 graduate students and 13 undergraduates during the grant period.
  •  Social: Centers equity by partnering with organizations that serve underserved populations, ensuring that the benefits of this innovation are shared widely.

Encouraged by strong results and stakeholder enthusiasm, the ReSpool team is now preparing to scale up their technologies, deepen community partnerships, and further develop a transferable model that other regions can adopt. With its unique blend of science, design, and social impact, ReSpool is creating a future where fashion waste is not a problem—but a resource.

 


Last Modified: 03/26/2025
Modified by: Kelly A Cobb

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