Fibre Extrusion Technology Ltd (FET), based in Leeds, UK, has unveiled its latest innovation — the FET-500 Series of gel spinning systems — a development set to transform the research and production of ultra-high-molecular-weight polyethylene (UHMWPE) fibres.
For years, FET has led the way in medical fibre extrusion technology, providing high-performance extrusion systems used in developing both resorbable and non-absorbable sutures. Its advanced equipment enables adaptable, small-scale production, allowing rapid and efficient new product development across the medical textile sector.
Addressing the Market Gap in UHMWPE Fibre R&D
Demand for UHMWPE fibre R&D has risen steadily due to the fibre’s exceptional strength, low weight, and durability. Despite its potential, innovation has been limited. Current large-scale production processes are often rigid and complex, focusing mainly on established fibre grades. This traditional approach has restricted experimental flexibility and slowed down new applications in biomedical and industrial fields.
The FET-500 Series addresses this long-standing limitation. The system offers a versatile and reliable process, producing high-quality UHMWPE fibres using less than 100 grams of polymer. It also avoids harsh and toxic processing chemicals that were once standard in gel spinning methods.
At the heart of this innovation is a patent-pending technology that uses supercritical carbon dioxide (CO₂) as a green solvent, enabling cleaner, safer, and more sustainable fibre production.
Sustainable and Efficient Gel Spinning Technology
While extrusion remains the first step in gel spinning, the washing and drawing processes are equally crucial for determining the yarn’s final performance. FET’s Patent Pending CO₂-based washing system introduces multiple environmental and operational advantages:
- Green Solvent Extraction: Removes carrier oil without harmful chemicals such as hexane or dichloromethane (DCM).
- Eco-Friendly Solvent: CO₂ is non-toxic, inexpensive, abundant, and safe to handle.
- Operational Efficiency: Offers a vast reduction in solvent use, comprehensive oil recovery, and zero solvent waste compared to traditional hexane methods.
- Compact Design: A recipe-controlled, plug-and-play system, scalable to customer requirements, with 80% less factory footprint.
- Circular System: The recovered carrier oil is recycled back into the extrusion process, minimizing waste.
These features make the FET-500 Series not only a technological upgrade but also a sustainable alternative that supports greener manufacturing practices in fibre extrusion.
FET’s Fibre Development Centre – The Core of Innovation
The success of the FET-500 Series is strongly supported by FET’s Fibre Development Centre in Leeds. This in-house facility enables the company to test, refine, and demonstrate the system’s full potential.
Customers can visit the centre to experience a complete demonstration line, observing the end-to-end fibre production process. The facility also provides R&D support, helping clients develop new products, optimise processing parameters, and scale innovations from the lab to full production.
Through this approach, FET offers a low-risk, high-value pathway to commercialising next-generation UHMWPE fibres for biomedical and high-performance textile markets.