Acoustic and mechanical performance of composites fabricated from post-industrial garment cutting room waste

Post-industrial garment cutting-room waste is a large-volume, low-value resource that has considerable potential as a sound-absorbing material of sustainable origin. In this work, the capability to transform cutting-room waste into high-performance acoustic composites that are also mechanically sufficient for non-load-bearing acoustic applications is demonstrated. The four pre-sorted waste streams (denim woven, cotton woven, cotton knit, and jute-woven) were mechanically shredded and chemically pretreated to produce one-layer composite panels using a dual-matrix system composed of polyurethane as the structural matrix, with polyvinyl acetate being added as a film-forming binder. Scanning electron microscopy (SEM) was employed to investigate microstructural features, tensile, flexural, and impact properties were evaluated according to the ASTM standard, and sound absorption coefficients (SAC) and noise reduction coefficient (NRC) were determined by performing acoustic tests using a normal incidence impedance tube. All composites show very high acoustic performance as characterized by the SAC, whose values are > 0.95 for most of the frequency range (500–5000 Hz) and NRC ranging from 0.93–0.99. The jute woven composite records the highest broadband absorption (NRC ≈ 0.99) while cotton woven and cotton knit composites exhibit better tensile (≈ 0.76 MPa) and flexural strength (≈ 17.6 MPa), respectively. The SEM examination demonstrates the connected porosity network, fiber pullout, and surface roughness to account for the controlling noise dissipation mechanisms on acoustic performance. The findings show that the dual-matrix design allows for stabilization of porous architecture without pore sealing, thereby partially mitigating the typical trade-off between acoustic performance and mechanical stability under non-load-bearing service conditions. The results imply that clean cutting-room waste is a technically meaningful input material transcending traditional synthetic absorbers, compatible with circular-economy-driven noise control properties. • Cutting-room textile waste was processed into a double matrix system acoustic composites, ensuring porosity and durability. • A remarkably high acoustic performance (SAC > 0.95; NRC 0.93–0.99) was achieved by all composites. • Jute waste showed the highest NRC value, and cotton-based waste provided comparatively better mechanical strength. • Results verify pre-sorted cutting-room waste as a valid circular economy substitute for synthetic acoustic absorbents.