Extensive fashion and textiles research have adopted fused filament fabrication in three-dimensional printing. However, much research has dedicated itself to experimenting with rigid materials that lack the capability to mimic conventional textile-like garments. The commercialization of thermoplastic polyurethane/elastomers have posed greater potentials for developing flexible polymer-textile composites. Such materials will enable the creation of ergonomically designed textiles with optimized flexibility and elasticity aimed for garments. This study examines the influence of polymers, textile surface roughness, and nozzle temperature on peel resistance and polymer coefficient of friction/surface roughness. T-peel tests (ISO 11339:2022), cross-sectional microscopic image analysis, and a KES-FB4-A surface tester were used to evaluate the surface quality and peel resistance between polymer-textile assemblies. Our results revealed thermoplastic-polyurethane-knitted combinations to demonstrate superior peel resistance owing to knitted structure’s pore structure and thermoplastic polyurethane’s lower melting temperature. Moreover, a significant increase in peel strength was found at 260°C (above recommended printing temperature) in thermoplastic-polyurethane-knitted fabrics at 3.24 N/mm. While the coefficient of friction remained similar, a rougher surface quality was discovered at higher temperatures in thermoplastic polyurethane at 3.85 μm warp/4.35 μm weft. In thermoplastic elastomer, the roughest surface was found at 240°C measuring 3.65 μm warp/3.37 μm weft. This study fills a lack of research into flexible polymer-textile composites by suggesting parameters for achieving an equilibrium between optimal adhesion and polymer layer surface quality.
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