10181955Unlocking the Full Resource Potential of Seaweed for Circular Stretch FibresClosedCollaborative R&DInnovate UKOur work focuses on developing a seaweed-based stretch fibre to replace synthetic elastane in textiles, providing equivalent comfort and elasticity while integrating into current processes and eliminating the environmental problems associated with fossil-based fibres. The focus of this project is investigating near-100% utilisation of UK seaweed in producing stretch fibres, dramatically improving resource efficiency. Elastane is used in almost every stretch garment, yet it prevents textile recycling, sheds microplastics, and emits around 17 kg CO2 per kilogram of fibre---more than polyester. Because fabrics containing elastane cannot be mechanically recycled, they contribute to the 350,000 tonnes of clothing sent to UK landfill each year, representing about £140 million of lost material value. Replacing elastane with a circular, bio-based alternative would transform the textile industry's transition to low-carbon, resource-efficient materials. The UK underwear sector alone used about $570 million worth of elastane in 2023, highlighting a major opportunity for sustainable substitution and decarbonisation. Our innovation is a seaweed-based stretch fibre, created through a low-temperature, solvent-free lab-scale wet-spinning process, built for industry-scale manufacturing. Building on our established lab-scale system, this project will explore integrating currently unused seaweed byproducts into the fibre formulation, enabling near-total use of seaweed for this novel application. This approach not only reduces waste and improves circularity but also has the potential to enhance the mechanical and textile performance of the resulting fibres. Through a series of laboratory trials, we will test how these seaweed components can be integrated into fibre production to achieve performance suitable for textile use. The results will inform the next phase of pilot-scale spinning and fabric testing with manufacturing partners. If successful, this innovation could replace a high-impact synthetic fibre with a renewable, low-carbon alternative, helping the UK reduce its reliance on petrochemical materials, cut textile waste, and bring greater value to the UK seaweed industry.