Melt spinning of textile fibres

RISE pilot melt spinning equipment.

Applications of our melt spinning R&D services

Melt spinning is the most widely used method for producing synthetic textile fibres, enabling cost-efficient and scalable fibre manufacturing. At RISE, we combine expertise in melt spinning and fibre post-processing to support innovation across diverse application areas.

Examples of applications includes:

• Apparel, sportswear and workwear – fibres with comfort, durability and performance.
• Upholstery and homeware – fibres combining functionality and aesthetics.
• Industrial and technical textiles – fibres for demanding environments.
• Functional textiles – fibres with added properties such as conductivity, piezoelectricity, temperature regulation, flame retardancy, resistance to soiling or anti-bacterial performance.

Melt spinning capabilities - from lab to pilot scale

At RISE, we provide melt spinning capabilities from early-stage material evaluation to pilot-scale production. Our facilities include fibre extrusion equipment ranging from small-scale (10 g) monofilament extrusion—ideal for testing spinnability of new materials—to lab and pilot-scale melt spinning lines with production rates from 0.1 to 7 kg/h. Our equipment also has the possibility to combine several polymers in one fibre through multicomponent features.

Our offer includes:

• Evaluating spinnability of new materials - including rheology, thermal analyses and small-scale melt spinning.
• Development of functional fibres and yarns – using additives, different cross-sections or multi-component features.
• Lab-scale melt spinning – from mono to bi-component fibres, enabling material evaluation and proof-of-concept development.
• Pilot-scale melt spinning – from mono to quad-component fibres, enabling scale-up towards industrial production. Possibility to make POY, FDY and staple fibres. 

Microscope images of fibers with different cross-sections. On the left is a four-component trilobal cross-section, where each component contains different pigments. On the right is an “islands-in-the-sea” cross-section, in which one polymer forms the dispersed cores while another polymer surrounds them as a continuous matrix.

Further testing and prototyping of melt spun fibres and yarns

Our melt spinning experts collaborate closely with RISE’s chemistry, polymer, and textile teams to support research and development across the entire fibre and yarn value chain. From early-stage material testing to advanced prototyping, we provide tailored solutions that accelerate innovation and ensure high-quality performance.

• Chemical and thermomechanical recycling – supporting sustainable polymer and fibre development.
• Post-processing of fibres and yarns – including texturing, twisting, nonwoven development, yarn spinning, and knitting.
• Comprehensive testing lab – standardised textile testing to verify quality and performance.
• Physical and chemical characterisation – using TGA, DSC, FTIR, and XRD to evaluate raw materials and finished fibres.
• Advanced microscopy – scanning electron microscopy (SEM) to study fibre cross-sections and particle distribution for precise material insights

Contact our melt spinning experts

Interested in exploring melt spinning solutions or prototyping innovative fibres and yarns? Our experts are ready to collaborate with you on research and development projects, from lab-scale trials to pilot production.