Sustainable Fabrication of Structurally Colored Nonwoven Fabrics via Coaxial Airflow Spinning for Eco-Friendly Traditional Chinese Patterns

Structurally colored fibers are crucial materials; however, the direct formation of aggregate materials from structurally colored fibers is challenging. This study presents a one-step method for preparing structurally colored fiber aggregate materials that inherently avoids traditional dyeing processes, thereby eliminating the discharge of toxic wastewater and reducing resource consumption in textile production. Nonwoven fabrics comprising structurally colored core–shell fibers were prepared via coaxial airflow spinning, wherein a polyethylene oxide (PEO) spinning solution was used to form the fiber core, and a SiO2 nanoparticle dispersion was used to form the fiber shell. This dye-free fabrication strategy integrates coloration directly into fiber formation, circumventing energy- and water-intensive postdyeing treatments. The SiO2 nanoparticles adhered to the fiber surface and exhibited both short-range order and long-range disorder, resulting in noniridescent structural colors with long-term stability, further minimizing the need for maintenance or replacement due to fading. The maximum tensile stress and strain of the structurally colored nonwoven fabric were 223.74 kPa and 87.44%, respectively, demonstrating mechanical robustness suitable for practical applications while maintaining eco-efficient production standards. Finally, the prepared fabrics were applied to produce traditional Chinese patterns, showcasing their potential as sustainable alternatives to conventional dyed textiles in cultural heritage preservation and green manufacturing initiatives.