Exploring the durability of fused deposition modeling (FDM) 3D printing on direct-to-textiles and textile-like structures

Purpose This paper aims to explore the application of fused deposition modeling (FDM) 3D printing technology on textiles to produce structures suitable for textile and fashion design that demonstrate enhanced resistance to abrasion and increased tensile strength. The research focuses on two key approaches: direct 3D printing onto fabrics and the creation of textile-like structures using various filament materials. Design/methodology/approach This study investigates FDM 3D printing applied directly to polyester and cotton fabrics using a range of filaments, including polylactic acid (PLA), polyethylene terephthalate glycol (PET-G), nylon (PA) and thermoplastic polyurethane (TPU). Abrasion resistance was evaluated for the directly printed samples. In the second phase, textile-like structures were produced from TPU, PET-G and PA and tested for tensile strength. Material type, application conditions and design characteristics were analyzed through both intra-group and inter-group comparisons. Findings The results demonstrate that both material selection and design features significantly influence the mechanical performance of 3D-printed textiles. In particular, surface smoothness and structural complexity affect abrasion resistance and tensile strength, revealing the importance of tailored material–design integration for functional outcomes. Originality/value This study contributes to additive manufacturing in textiles by offering a unique comparative analysis of direct-to-fabric printing and the fabrication of textile-like structures. By identifying the critical impact of material-design integration on abrasion resistance and tensile strength, this research provides a strategic foundation for enhancing the durability and customization of functional 3D-printed textiles.