Laser-textured nonwovens for reduced stain visibility

Overview

This technology applies femtosecond or pulsed laser texturing to nonwoven topsheets and acquisition layers used in disposable hygiene products. The dry, non-contact process creates directional microchannels, hierarchical surface features, and wettability gradients that rapidly transport menstrual fluid and red blood cells away from the visible surface into deeper layers. Concurrently, the laser-induced topography increases light scattering and opacity, optically concealing residual colored components without chemical decolorization.

The solution directly targets post-use stain visibility—a key consumer concern—by combining two complementary physical mechanisms: structural transport of fluid away from the visible surface, and optical concealment of any remaining color. This dual approach requires minimal changes to existing pad construction, preserves fluid acquisition, dryness, comfort, and leak protection under compression, and integrates optical and structural functions into a single scalable material solution.

Technical specifications

Key features:

• Femtosecond or pulsed laser texturing creates directional microchannels for rapid fluid transport away from the visible surface
• Hierarchical surface features and wettability gradients move menstrual fluid and red blood cells into deeper nonwoven layers
• Laser-induced topography increases light scattering and opacity to optically conceal residual color
• Completely dry, non-contact process—no chemical decolorization agents required
• Compatible with commercial nonwoven topsheets and existing pad construction
• Preserves fluid acquisition, dryness, comfort, and leak protection under compression
• Single material solution integrating optical and structural functionality

The texturing process can be tuned by adjusting laser parameters (power, pulse duration, scan pattern) to optimize the balance between fluid transport performance, optical concealment, and surface softness for consumer comfort.

Technology readiness level

The technology is at an early development stage (TRL 3–4). A 12-month validation program is planned: months 1–3 will select commercial nonwoven topsheets, establish baselines for fluid acquisition, rewet, optical appearance, and mechanical properties, and optimize laser parameters. Months 3–7 will validate performance—directional transport, stain visibility reduction using realistic simulants or blood, compression resistance, and comfort—iterating against control materials. Months 7–10 will integrate optimized layers into pad prototypes and evaluate fluid handling, leak protection, and post-use appearance under realistic conditions, including limited durability screening. Months 10–12 will produce a technical report, process documentation, material samples, and scale-up recommendations.