Low-add-on electrospun nanofiber barrier layer for breathable nonwovens
A film-free liquid barrier structure that combines an ultra-low-basis-weight electrospun nanofiber layer with a lightweight nonwoven substrate, providing liquid penetration resistance while preserving air and moisture-vapour transport, softness, and flexibility for breathable barrier applications.
Overview
This technology offers a film-free barrier structure created by directly electrospinning an ultra-low-basis-weight nanofiber layer onto a lightweight synthetic nonwoven. The nanofiber layer forms very small pores and a tortuous path that improve liquid penetration resistance, while the supporting nonwoven provides strength, softness, and flexibility. The result is a breathable barrier that balances protection with comfort and cost, suitable for applications where liquid resistance and wearability must coexist.
The approach builds on demonstrated experience in scaling electrospun nanofiber layers on nonwoven substrates for respirator filtration, providing a practical starting point for adapting the platform to barrier and comfort requirements.
Technical specifications
The development plan focuses on optimizing polymer selection, nanofiber add-on weight, fiber diameter, pore structure, and surface wettability to balance barrier performance, breathability, softness, and cost.
Key parameters under development include:
- Lightweight spunbond substrate, approximately 5–20 gsm
- Nanofiber layers of approximately 2–10 gsm
- Hydrophobic electrospun polymer system for liquid resistance
Validation will screen hydrohead, air permeability, water-vapour transmission rate (WVTR), softness, tensile properties, and strike-through using representative fluids to confirm performance across the key barrier and comfort metrics.
Technology readiness level
The technology is in the early development and validation stage. Work is planned in four stages: substrate and polymer system selection, nanofiber layer fabrication and optimization of fiber diameter, pore size, wettability, and coating uniformity, performance screening, and scale-up using roll-to-roll nanofiber coating experience. The final stage involves producing pilot samples and optimizing cost and process parameters. Prior scale-up of electrospun nanofiber coatings on nonwoven substrates for respirator media supports the pathway toward industrial deployment.
About NTP R&D Services Ltd
NTP R&D Services Ltd, operating as NTP Research, is a Canadian nanotechnology company that specializes in the development and commercialization of electrospun nanofiber delivery platforms. The company bridges the gap between laboratory-scale research and industrial-scale manufacturing by providing a flexible technology platform that enables the creation of high-surface-area delivery systems. These systems are used to deliver active ingredients through oral mucosa or transdermal patches, offering advantages such as rapid dissolution, enhanced stability for heat-sensitive compounds, and improved absorption by bypassing gastrointestinal degradation. Their service model includes formulation support, prototype development, and scalable manufacturing pathways for partners across the nutraceutical, pharmaceutical, and skincare industries.
This technology is significant for customers seeking to improve the efficacy and user experience of their active ingredients. By moving away from traditional, less efficient delivery methods—such as large capsules or heavy creams—brands can offer consumers dissolvable, targeted solutions like the company's NFPatch for skincare recovery or oral thin films for supplements. The company supports partners from the conceptual stage through to production, assisting with customization of patch shapes, thicknesses, and active loading. NTP has demonstrated the viability of its platform through clinical evaluations and by helping brands successfully translate laboratory innovations into consumer-ready products.
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