Opportunities

Call for U.S. Textile Mill Participation in Pilot-Scale Fabrication of Reinforcement Material for Electrolyzer Membranes 

Overview 

Advanced Functional Fabrics of America, Inc. (AFFOA), in partnership with Z-Polymers, is seeking U.S.-based textile manufacturing partners to participate in a pilot-scale production trial of a novel reinforcement fabric designed for electrolyzer membranes used in fuel cells. In addition to this primary application, Z-Polymers is actively exploring additional opportunities in screen printing and filtration using similar fabric constructions. Furthermore, ongoing yarn development efforts are expected to expand the application space of Tullomer™-based textiles, enabling new market opportunities across a variety of high-performance sectors. 

This initiative builds upon a successful lab-scale development effort completed in 2023–2024 by the AFFOA technical team under the Product Accelerator for Functional Fabrics (PAFF 1.0) program.  

Z-Polymers’ proprietary Tullomer™ fiber was developed over the course of AFFOA’s PAFF 1.0 initiative. During that period, AFFOA collaborated with Z-Polymers to convert its proprietary composite yarn into scrim fabric using automated equipment, including the CCI Studio Dobby Loom. AFFOA also produced sample fabrics that enabled Z-Polymers to provide prospective customers with early prototypes for evaluation. Approximately 15M of fabric was woven. Various samples were prepared for customer evaluation, some examples of these at three different pick counts (Weft 70, 75, 80 ppi/Warp 70 epi) are shown in the appendix of this document. 

The current effort is supported under PAFF 2.0, where Z-Polymers has been selected to further scale and commercialize this innovative solution. AFFOA will support Z-Polymers in identifying and engaging suitable textile mills across the U.S. to carry out pilot-scale production and validation of the fabric. 

Why Partner on This Pilot? 

• Advanced Material Advantage: The fabric leverages Tullomer™, a proprietary PFAS-free liquid crystal polymer (LCP) developed by Z-Polymers, offering unmatched thermal, chemical, and environmental performance. It presents a sustainable alternative to conventional materials such as expanded PTFE (ePTFE). 

• Target Application: The fabric will serve as a reinforcement layer for electrolyzer membranes, addressing critical performance and sustainability challenges in fuel cell systems. The fabric also performs in products used for filtration, screen-printing, and electronics. 

• Growing Market Demand: Z-Polymers is experiencing early interest from prospective customers in the clean energy sector who are seeking high-performance, environmentally responsible material solutions. This growing demand underscores the market potential for Tullomer™-based scrim fabrics in applications such as energy storage and fuel cells. 

Below are the projections provided to Z-Polymers by its launch customer for this specific market. The volume of 2M m2 represents about 10% market share, while customer’s actual market share is 35 – 40% in the segment (conservative estimates for valuation purposes). The product roadmaps for the tullomer and multifilament fibers are located in the appendix of this document. 

• Technology Enablement: By participating in this initiative, textile mills have the opportunity to work with cutting-edge functional materials and play a leading role in next-generation fabric applications. This collaboration opens the door to strategic partnerships with Z-Polymers and AFFOA, and positions participants at the forefront of innovation in clean energy and advanced composites. 

• Future Markets: Z-polymers is currently developing multifilament yarn that will be used for woven scrim fabrics. Textile mills who collaborate on this pilot program also have the additional potential opportunity to directly work with Z-Polymers on this multifilament construction. 

• Fabric Conversion Specifications 

The fabric conversion specifications are created by AFFOA Lead Textile Technologist Gabrielle Ferreira, based on the lab trial conducted at AFFOA through the PAFF 1.0 project. That document, the tullomer scrim fabric date sheet and images of the previously woven fabric can be found in the appendix of this document. 

About Z-Polymers 

Z-Polymers is a materials science company focused on advanced polymer innovation. Its proprietary Tullomer™ platform is a PFAS-free liquid crystal polymer exhibiting: 

• Exceptional strength-to-weight ratio 

• Outstanding chemical resistance and thermal stability 

• Low outgassing and low toxicity 

• Low flammability (chars, no drip) 

• Ultra-low carbon footprint 

Tullomer™ is currently available in multiple formats, including multifilament yarns suitable for woven, and nonwoven fabric production.
Learn more: https://z-polymers.com 

About Advanced Functional Fabrics of America, Inc. (AFFOA) 

AFFOA is a non-profit, public-private partnership and one of the Manufacturing USA Innovation Institutes headquartered in Cambridge, MA. AFFOA’s mission is to “Rekindle the domestic textiles industry by leading a nationwide enterprise for advanced fiber & fabric technology development and manufacturing, enabling revolutionary system capabilities for national security and commercial markets”.   https://affoa.org/  

 About Product Accelerator for Functional Fabrics (PAFF) Program 

Launched in 2024, the PAFF program enables selected companies to leverage AFFOA’s technical engineering team with expertise in advanced textiles across design, prototyping, integration, testing, and process engineering at no direct cost to fill critical gaps in their functional fabric development processes and ultimately reduce time to market. https://affoa.org/opportunity/paff-2-0-product-accelerator-for-functional-fabrics/  

How to Participate 

If you are interested in participating in this opportunity and learning more about the details, please contact the AFFOA team for the next step 

Gabrielle Ferreira
Lead Textile Technologist
Advanced Functional Fabrics of America (AFFOA)
gferreira@affoa.org  

Dr. Guan Wang
Ecosystem Technology Manager
Advanced Functional Fabrics of America (AFFOA)
gwang@affoa.org 

To be considered for future AFFOA collaboration projects, please complete the following: 

[Vendor Survey Form – Z-Polymers Pilot Trial]
This form collects essential information on your mill’s capabilities, production equipment, material handling experience (especially with high-performance yarns), and availability to support future trials. 

Deadline to Submit: June 15th, 2025 

Response Deadline: 06.15.2025

• Topic #: knitting mill opportunity
• Technology Areas: Weaving
• Link:

RFI# AFFOA-CROSSFIT

1. Background

High-intensity and/or extended missions are encountered throughout defense operations & training, which induce fatigue and injury to the Warfighter. Countermeasure technologies are needed to accelerate recovery and return to mission-ready status for the warfighter. AFFOA, in collaboration with the US Department of Air Force and the Air Force Research Laboratory, is seeking wearable devices designed to accelerate recovery and/or provide in-operation performance support related to sleep, musculoskeletal system (MSK) recovery, or cognitive recovery. Of specific interest are commercial-off-the-shelf wearable device systems that are suitable for use in scenarios associated with various Military Occupational Specialties (MOS), and are at a manufacturing maturity for scale-up to commercialized production.

1.1. Purpose and objectives

AFFOA is seeking emerging technologies that are viable for accelerated Warfighter recovery. Of particular interest are wearable technologies with textile-based form factors. Please note that acceptable devices for this study must include an active recovery mechanism; data collection alone is not sufficient.

Systems should have the following attributes:

· Manufacturing Readiness Level (MRL) 6+

• (Produce prototype system in a production-relevant environment)

· Commercial Off the Shelf (COTS) or “emerging” COTS

· Appropriate for daily use

· Intent for Made in USA, and/or roadmap to US manufacturing

AFFOA will perform a destructive teardown analysis of selected products, develop a manufacturing readiness level (MRL) and technology readiness level (TRL) assessment of related subcomponent materials and devices, identify a bill of materials (BOM), and document limitations for these wearable devices as they relate to integration, reliability, and scalability. Downselected companies will be expected to provide 1-2 functional samples of their products and work with the AFFOA team to answer questions regarding their manufacturing processes and design philosophy. Findings will be shared with the organizations who provided the selected products, as well as government sponsors.

2. Timeline

45-day open call from April 28, 2025 to June 13, 2025.

3. Company Eligibility

Eligibility for this program is limited to companies with a desire to manufacture in the US. Past manufacturing does not need to be domestic, however a vested interest in the development of a roadmap towards US manufacturing is a requirement. AFFOA membership is not a requirement for participation.

4. Application and Submission Information

AFFOA is requesting that organizations submit proposals for the inclusion of their wearable recovery devices in this study. Proposals for inclusion should contain the following:

1. Description of device, associated technologies and form factor, what does it do, and how does it do it? Please include pictures of the product, and/or a link to commercial product if available.

2. Any related studies or test results that can attest to the efficacy of the product, comments on the benefit to the warfighter, and any previous demonstrations and feedback if known.

3. Comments on system readiness – has it been manufactured? How many units? Is the device available to purchase at time of RFI?

Applications must be received by AFFOA by no later than 11:59 pm Eastern Time, Friday, June 13, 2025. Applications received after the deadline may not be considered or evaluated.

The RFI response should be submitted to jslade@affoa.org.

Disclaimer

This is an RFI only. The Advanced Functional Fabrics of America (AFFOA) will not pay for any RFI developed or submitted. All costs incurred responding to this RFI will be solely at the interested party’s expense. Failure to respond to this RFI will not preclude participation in any future solicitation.

This RFI is not associated with any Air Force or other DoD acquisition program and shall not be construed as a solicitation nor is participation a requirement for other government-funded opportunities

All responses that include business confidential or proprietary information should be clearly marked.

Upon review of all RFIs received, additional terms and conditions and/or ownership and use rights of the device may be requested for downselected systems.

Response Deadline: 06.13.2025

• Topic #: medical
• Link: