#Research & Development

2023-02-01

Digital platform: producing custom-fit orthoses quickly, resource-efficiently and cost-effectively

Hand-held 3D scanners can be used to digitize patient body parts as the basis for flexible textile orthoses. Photo: DITF

Resource efficiency, time and cost savings are essential topics in the textile and apparel industry. Conventional supply and production chains often reach their limits, as products need to individually be tailored and available in a short time. The trends of the future are therefore called "fast fashion" and "microfactory". The advantages of digital manufacturing apply not only to fashion, but also to medical textiles.

To this end, the German Institutes of Textile and Fiber Research Denkendorf (DITF) have developed a digital platform that can be used to produce precisely fitting flexible textile orthoses in a resource-, time- and cost-efficient manner.

Carrying out a patient screening with digital measurement. Photo: DITF

Until now, orthoses have primarily been made manually, which leads to a high error rate. Digitally based manufacturing chains can significantly reduce this waste. For the digital platform, the body data of patients was analyzed and processed at the DITF, on the basis of which standardized orthoses can be developed. Therefore, various body scanning methods were investigated and methods were developed for taking precise body measurements. The information from the screenings was condensed and a digital basic pattern or pattern module database was created.

From this database, the individual model fitting to the patients is carried out. Therapeutic fit is verified using an avatar in 3D simulation software. The finished digital pattern designs are transferred to a cutter, where they are machine-cut to size from elastic fabrics. It is also possible to print the pattern on a plotter/printer as templates and then cut them manually.

The cuts are then processed into finished textile orthoses.

Textile climate control system in workwear – exhibition at the 2026 SME Innovation Day!

Conventional protective workwear often reaches its limits during strenuous physical activity. In particular, the transport of sweat and excess body heat poses a problem. The German Institutes of Textile and Fiber Research (DITF) conducted research on flow-optimized, air-conducting textile structures that enable targeted climate control directly on the body. These structures can be integrated straight into protective work garments. The textile climate control system supports the body’s natural thermoregulation. This contributes to improved workplace safety and comfort.

Stylish design made from sustainable materials – two DITF research projects receive Techtextil Innovation Awards

Materials made from domestic, renewable raw materials reduce CO₂ emissions, prevent microplastics from entering the environment, and close the material cycle. The German Institutes for Textile and Fiber Research Denkendorf (DITF) are developing nature-based alternatives to synthetically produced and predominantly petroleum-based materials. Two research projects have received a prestigious Techtextil Innovation Award. NUO Flexholz and the lignin-coated material FormLig demonstrate that sustainable concepts can meet high standards of functionality and design. Both projects were carried out in close collaboration with industry.

Fabolose: Fabricating vegan and circular leather alternatives from bio-tech-derived cellulose

Fabulose is an EU funded project coordinated by the German Institutes of Textile and Fiber Research (DITF). Its consortium consists of leading research institutes, biotech innovators, and industry stakeholders who aim to create high-performance, biobased and recyclable leather-like fabrics, using efficient biotech production routes for bacterial cellulose, cyanophycin and bacterial pigments

TCLF: Resilient value chains in times of crises

The textiles, clothing, leather and footwear (TCLF) industry was at the centre of the webinar “Resilient value chains in times of crises”, which took place on 28 April 2026. Global supply chains continue to face increasing pressure, raw material dependencies are growing and economic uncertainties are affecting the entire sector.

Elastic yarns to become more recyclable and environmentally friendly in future

On 29 April 2026, ITA student Tobias Dickmeiß was awarded a sponsorship prize by the Wilhelm Lorch-Stiftung for his innovative approach, to replacing conventional elastane with elastic yarns made from thermoplastic copolyester elastomers (TPC). Thanks to their thermoplastic nature and compatibility with typical polyesters used in the textile industry, elastic TPC yarns offer improved recyclability. Furthermore, the use of the melt-spinning process in yarn production eliminates the need for solvents that are harmful to the environment and human health.

Walter Reiners Foundation Prize awarded to three ITA graduates

Sabina Dann, Lukas Balon and Annegret Storm from the Institut für Textiltechnik (ITA) of RWTH Aachen University were awarded the Walter Reiners Foundation Prize by the German Engineering Federation (VDMA) for their master’s and bachelor’s theses. Peter Dornier, Chairman of the Walter Reiners Foundation, presented the awards during Techtextil at the VDMA stand in Frankfurt am Main, Germany.

Young talents honoured – 60 years Walter Reiners Foundation

At the Techtextil trade fair in Frankfurt at the end of April, Peter D. Dornier, chairman of the VDMA’s Walter Reiners Foundation, presented awards to five successful young engineers. Promotion and sustainability awards were presented in the categories of bachelor’s/project theses and diploma/master’s theses. Academic theses are eligible for the sustainability awards if, for example, they develop solutions for resource-efficient products and technologies.

SHIMA SEIKI to show complete knitting and cutting workflow at ITM 2026

Leading computerized flat knitting technology provider SHIMA SEIKI MFG., LTD. of Wakayama, Japan, together with its Turkish representative TETAS IC VE DIS TICARET A.S., will participate in the ITM 2026 International Textile Machinery Exhibition in Istanbul, Türkiye this month with a full product lineup. In addition to flat knitting machines and design software, visitors will also have the opportunity to experience the full range of SHIMA SEIKI textile machinery with its automatic cutting machine exhibit, all geared toward the fashion apparel market as well as non-apparel related businesses.

European Flax-Linen & Hemp step into advanced manufacturing: Enabling filament winding, 3D printing and high-performance composite processes

The Alliance for European Flax-Linen & Hemp announces a new wave of technological advancements demonstrating how flax-linen and hemp fibres are now being successfully integrated into advanced composite manufacturing processes. These developments mark a transition beyond traditional hand lay-up techniques, positioning natural fibres as credible, scalable solutions for high-performance industrial applications.