The development of multifunctional cellulose-based textiles through sustainable manufacturing processes is increasingly important. While zinc oxide (ZnO) nanoparticles are effective for the shielding and antimicrobial effects, conventional incorporation methods involve energy-intensive and solvent-heavy processes that hinder scalability and environmental compatibility. Here, we present a green and scalable solid-state conversion route for directly synthesizing ZnO nanorod coating on cotton fabric. By immersing fabrics in precursor aqueous solutions followed by a dry-cure thermal treatment, dense and uniform ZnO layers with controllable nanorod morphology are achieved. The well-adhered ZnO nanorod with controllable loading content were proportional to precursor concentration. Structural evolution during solid-state conversion of precursor to ZnO coating was investigate. The composite cotton fabrics exhibit robust hydrophobicity, good breathability and excellent wearer comfort. Moreover, the coatings demonstrate exceptional wash durability after laundering while delivering sustained UV and antimicrobial protection, owing to the exceptionally strong interaction between ZnO nanorod and cotton fabric substrate. This green synthesis route offers a scalable, inexpensive, and controllable approach to produce ZnO coated cotton fabrics, providing a practical solution compatible with conventional processing equipment to produce high-performance protective textiles while ensuring both wearer comfort and environmental safety. We present a green and scalable solid-state conversion method for directly synthesizing zinc oxide (ZnO) nanorod coatings on cotton fabric. This process involves simple immersion in a zinc acetate solution followed by dry-cure thermal treatment process, resulting in uniform ZnO growth. The resulting functional cotton fabric exhibited good tensile strength, laundry durability, wearer comfort, breathability and hydrophobicity, alongside excellent UV shielding and superior antibacterial activity. This environmentally friendly and inexpensive approach is compatible with existing textile manufacturing, offering a practical route to produce high-performance, comfortable, and sustainable cellulose-based textiles. • A sustainable solid-state conversion route fabricates ZnO nanorod coatings directly onto flexible cellulose-based fabrics. • The ZnO-coated fabrics exhibit robust coating stability, good breathability, and excellent wearer comfort. • Large-area, wash-durable fabrics achieve exceptional UV protection and antibacterial properties.
Diao et al. (2026) studied this question.