CAS Team's MARS Method Revolutionizes Superhydrophobic Fabric Fabrication

A groundbreaking advancement from China's research powerhouse, the Chinese Academy of Sciences (CAS), is set to transform the textile industry with the introduction of the MARS method for fabricating superhydrophobic fabrics. This innovative technique, developed by a team at the Technical Institute of Physics and Chemistry (TIPC), offers a fluorine-free, durable solution to long-standing challenges in waterproof textile production.4950

Superhydrophobic surfaces, characterized by water contact angles exceeding 150 degrees and low contact angle hysteresis, mimic the lotus leaf's natural water-repelling properties. These surfaces cause water droplets to roll off easily, carrying away dirt and contaminants—a phenomenon known as the lotus effect. In textiles, this translates to self-cleaning, stain-resistant, and waterproof fabrics ideal for outdoor gear, protective clothing, medical uniforms, and industrial applications. However, achieving this at scale while ensuring durability has proven elusive.50

The Dawn of MARS: Molecularly Assembled Robust Superhydrophobic Shell

The MARS method represents a paradigm shift in superhydrophobic fabric fabrication. Unlike traditional approaches that rely on spraying nanoparticles or fluorine-based compounds (per- and polyfluoroalkyl substances, or PFAS), MARS employs a one-step molecular assembly process to create a covalently bonded silica shell directly on individual fibers. This shell forms an ordered, nanoscale rough structure that imparts superhydrophobicity at the fiber level, even before weaving or knitting into final fabrics.4950

The process begins with immersing loose fibers—such as cotton, polyester, or nylon—in a precursor solution containing silica precursors and silane coupling agents. Under controlled conditions, including mild heating and pH adjustment, the molecules self-assemble into a hierarchical micro-nano structure on the fiber surface. Covalent bonds anchor the shell firmly, preventing delamination. Fibers are then dried and spun into yarns or fabrics without losing the effect. This compatibility spans natural (cotton, wool) and synthetic (polyester, nylon) fibers, making it versatile for China's vast textile sector, which produces over 50 billion meters of fabric annually.50

Key to MARS's success is its biomimetic design, inspired by natural robust surfaces like insect wings. The silica shell is thin (nanoscale) yet mechanically interlocked, ensuring the fabric retains breathability (moisture vapor transmission rate >2000 g/m²/24h), softness, and tensile strength comparable to untreated materials.

CAS Leadership: Prof. Dong Zhichao and the TIPC Team

Leading the charge is Prof. Dong Zhichao from TIPC-CAS, a specialist in bio-inspired interfacial materials. Co-authors include Zhuoxing Liu, Kexin Zhao, Jie Ma, and others from TIPC, the University of Chinese Academy of Sciences (UCAS), and Suzhou Institute for Advanced Research. Their interdisciplinary expertise in surface chemistry, nanomaterials, and textile engineering enabled this feat. Published in Nature Communications on March 20, 2026, the work has garnered three pending Chinese patents (CN 202610186197.5 et al.).50

CAS, China's premier research organization, plays a pivotal role in national innovation. TIPC, under CAS, focuses on physical chemistry and advanced materials, collaborating closely with universities like UCAS, where many team members hold positions. This breakthrough underscores CAS's contribution to China's 'Double First-Class' initiative, elevating materials science research and fostering talent in higher education. UCAS students and postdocs involved gain hands-on experience in cutting-edge labs, bridging academia and industry.49

The project's funding from the National Natural Science Foundation of China (NSFC) and CAST's Young Elite Scientists program highlights government support for young researchers, vital for sustaining China's R&D momentum amid global competition.

Unmatched Durability: Surviving Harsh Real-World Tests

MARS fabrics excel in rigorous testing. In Martindale abrasion (simulating wear), they retained superhydrophobicity after 50,000 cycles—far surpassing conventional coatings (fail after ~5,000). Taber abrasion tests showed similar resilience. High-speed droplet impacts (up to 4 m/s) and prolonged rain (equivalent to heavy storm) left no wetting.49

Environmental extremes were no match: stable at 160°C steam and -196°C liquid nitrogen. Simulated use—backpack friction (10,000 cycles), stretching (5,000 cycles), tape peeling (100 cycles), and dynamic activities like running—preserved performance. Unlike nanoparticle coatings that crack or PFAS films that leach, MARS's covalent bonding ensures longevity.50

Photo by Merakist on Unsplash

• Martindale abrasion: >50,000 cycles
• Water contact angle: >150° post-abrasion
• Hysteresis: <10° even after washing (50 cycles)
• Breathability: Unchanged

Overcoming PFAS: A Sustainable Revolution

PFAS, dubbed 'forever chemicals,' dominate commercial waterproofing but persist in environments, linked to health risks. Bans loom in EU (2026), US, and China pushing greener alternatives. MARS is fluorine-free, using safe silica, aligning with China's carbon neutrality goals and circular economy.50

This eco-friendliness, combined with low-cost precursors, positions MARS for mass adoption. China's textile market, valued at $300B+, stands to benefit, reducing import reliance on PFAS from abroad.

Applications Transforming Chinese Industries

In outdoor apparel, MARS enables ultra-durable rain gear for China's mountaineers and hikers. Protective clothing for firefighters, oil workers gains self-cleaning, reducing maintenance. Medical textiles resist fluids/bacteria, aiding infection control in hospitals. Industrial filters separate oil-water efficiently.49

China's functional textiles market grows 10% yearly, projected $50B by 2026. MARS supports 'Made in China 2025,' enhancing exports amid US tariffs.

Boosting China's Higher Education and Research Ecosystem

This CAS innovation exemplifies China's higher ed prowess. UCAS, CAS's university arm, trains 60,000+ students yearly in sciences. Collaborations with Tsinghua, Peking U accelerate tech transfer. MARS patents licensed to firms, creating jobs for materials grads.50

China's R&D spend hits 3% GDP, with universities producing 80% papers. Initiatives like NSFC fund such breakthroughs, drawing global talent. For Chinese colleges, MARS inspires curricula in smart materials, fostering startups via incubators.

Market Potential and Economic Impact

Global superhydrophobic coatings market: $30B (2024) to $217B (2033), CAGR 24%. China leads with 30% share, textiles segment $10B+.28 MARS cuts costs 50%, scales via dipping lines, revolutionizing $400B Chinese textile exports.

Stakeholders: Textile giants like Texhong, research parks in Suzhou. Govt subsidies via MIIT boost commercialization.

Photo by Nick Fewings on Unsplash

Challenges and Future Directions

Challenges: Scaling to mega-factories, color integration. Future: Smart responsive shells, anti-bacterial variants. CAS plans trials with partners.49

Integrate with 6G wearables, space suits. Universities train experts via MARS-inspired labs.

Global Context and Chinese Leadership

While US/EU chase PFAS alternatives, CAS's MARS leads with durability. Patents protect IP, positioning China in $100B+ advanced materials market by 2030.

For Chinese higher ed, it signals rising global rank (Nature Index leader), attracting intl students to materials programs.