Applications and development trends of textile materials in sports: A review

Abstract

Sports textiles represent a rapidly evolving discipline at the intersection of material science, sports engineering, and human physiology, underpinning athlete performance, comfort, and safety. This review opens by highlighting the core physiological and ergonomic demands placed on athletes—effective thermoregulation, efficient moisture management, mechanical support and proprioceptive feedback—and then elucidates the fundamental mechanisms by which fiber architecture and fabric structure fulfill these requirements. We examine capillary-driven moisture transport through engineered micro- and nano-scale fiber networks, thermal buffering achieved via phase-change materials and inherently low-conductivity fibers, and dynamic compression effects arising from elastomeric yarns that improve circulation and stability. The manuscript then surveys cutting-edge material innovations, including smart textiles embedded with flexible sensor arrays, nanocoatings that confer water repellency, antimicrobial action and ultraviolet protection, and stimuli-responsive polymers that change shape or porosity in response to temperature and humidity. Multifunctional nanocomposites—combining carbon-based nanomaterials with polymer matrices—are reviewed for their dual capacity to reinforce mechanical properties and enable real-time physiological monitoring. An in-depth analysis of manufacturing processes follows, covering advanced fiber synthesis methods (electrospinning, wet spinning), high-precision spinning techniques for core–sheath and coaxial yarns, seamless knitting and 3D textile printing technologies, as well as strategies for integrating electronic components without compromising wearability. We critically assess standardized testing protocols for thermophysiological comfort, moisture management metrics, mechanical durability and endurance of smart functionalities under repeated laundering. A dedicated section on sustainability examines lifecycle impacts, emerging bio-based and recyclable fiber alternatives, closed-loop manufacturing, and approaches to mitigate microfiber shedding. Customization trends driven by digital manufacturing and on-demand production are discussed in terms of personalized fit, performance profiling and consumer aesthetics. Finally, we identify research gaps—such as long-term durability of smart textiles, integration of energy-harvesting systems and scalable eco-friendly process development—and propose strategic directions to accelerate the creation of next-generation, high-performance, environmentally responsible sportswear.