Pre-processing (dye and elastane removal): WP1)Pre-processing (dye and elastane removal): A very efficient color stripping method has been developed for dyed cotton fabrics, achieving up to 99% color removal with high tensile strength retention (94%). In parallel, an elastane removal route based on partial degradation was developed and shown to be effective for neat elastane; however, due to limitations on cotton–elastane blends, the work pivoted toward direct elastane dissolution as the preferred pathway for blended waste streams. This route is still under development. Fibre spinning (closed-loop wet spinning / dope-dyed fibre recycling): Three spinning technologies (viscose (RISE), NMMO-Lyocell (Aalto), and Ioncell (Aalto)) were evaluated for chemical recycling of dope-dyed cellulose fibres through comprehensive fibre characterization (morphology, chemistry, mechanical properties, and colour). All routes preserved dope-dyed colour properties. A key outcome was the strong mechanical performance of recycled Lyocell-based fibres, demonstrating high potential for high-quality regenerated fibres from recycled inputs. PFAS-free bio-based DWR: Formulation development progressed iteratively with SSbD guidance, resulting in ~50 formulations screened and DWR systems reaching 80–90% bio-based content at this stage. Durability testing showed performance loss after wear/washing, but importantly, water repellence could be partially/fully regenerated by heat treatment (e.g. spray score returning to 5 after heat following wear; partial recovery after wash cycles), providing a clear technical lever to improve lifetime performance without PFAS. PVC-free bio-based printing with in-built recyclability: A pigment selection framework was established using colloidal characterization (DLS/zeta potential) to identify surfactant–pigment stability trends. Screening highlighted a promising PLA + ethyl cellulose binder combination balancing viscosity control, film formation, and printability. Initial removability testing confirmed detachment behaviour comparable to reference reversible systems. During this first period initial hazard assessment has been performed of WP1- WP4 innovations. A BioSusTex-specific safety assessment method aligned with the JRC SSbD framework was developed, adapting criteria and thresholds to bio-based chemicals/materials and textile processes. Furthemrore, early-stage sustainability work was completed for initial screening, applying two qualitative methods (LCBROM and the SSbD Scoping Method) via structured workshops. ProScale development progressed to extend beyond worker exposure/production toward service-life/end-of-life and indirect environmental exposure. Work on absolute sustainability advanced through development of a prospective AESA approach integrating upscaling, scenario work, LCA and absolute evaluation. Finally, the SSbD decision-support approach was initiated, focusing on integrating WP5 safety outputs and WP6 sustainability outputs via MCDA. The DSS technical infrastructure was established on AWS, with containerized components deployed. The data layer was strategically shifted from MongoDB to a relational database to better match data complexity, and an interactive UI prototype was developed (Framer), providing the foundation for the first functional DSS prototype in the next period.
