The future of nylon: ladder-free hosiery

Last week I outlined the design for a 3D printer that can print and project graphene filaments at 100m/s. That was designed to be worn on the wrist like Spiderman’s, but an industrial version could print faster. When I checked a few of the figures, I discovered that the spinnerets for making nylon stockings run at around the same speed. That means that graphene stockings could be made at around the same speed. My print head produced 140 denier graphene yarn but it made that from many finer filaments so basically any yarn thickness from a dozen carbon atoms right up to 140 denier would be feasible.

The huge difference is that a 140 denier graphene thread is strong enough to support a man at 2g acceleration. 10 denier stockings are made from yarn that breaks quite easily, but unless I’ve gone badly wrong on the back of my envelope, 10 denier graphene would have roughly 10kg (22lb)breaking strain. That’s 150 times stronger than nylon yarn of the same thickness.

If so, then that would mean that a graphene stocking would have incredible strength. A pair of 10 denier graphene stockings or tights (pantyhose) might last for years without laddering. That might not be good news for the nylon stocking industry, but I feel confident they would adapt easily to such potential.

Alternatively, much finer yarns could be made that would still have reasonable ladder resistance, so that would also affect the visual appearance and texture. They could be made so fine that the fibers are invisible even up close. People might not always want that, but the key message is that wear-resistant, ladder free hosiery could be made that has any gauge from 0.1 denier to 140 denier.

There is also a bonus that graphene is a superb conductor. That means that graphene fibers could be woven into nylon hosiery to add circuits. Those circuits might be to harvest radio energy, act as an aerial, power LEDS in the hosiery or change its colors or patterns. So even if it isn’t used for the whole garment, it might still have important uses in the garment as an addition to the weave.

There is yet another bonus. Graphene circuits could allow electrical supply to shape changing polymers that act rather like muscles, contracting when a voltage is applied across them, so that a future pair of tights could shape a leg far better, with tensions and pressures electronically adjusted over the leg to create the perfect shape. Graphene can make electronic muscles directly too, but in a more complex mechanism (e.g. using magnetic field generation and interaction, or capacitors and electrical attraction/repulsion).

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