Developing robust water-repellent textiles is critical for outdoor, protective, and industrial applications. However, achieving long-lasting water repellency under mechanical stress has been a major challenge.

Now, a research team led by Prof. DONG Zhichao from the Technical Institute of Physics and Chemistry of the Chinese Academy of Sciences has developed a new one-step fabrication strategy—termed MARS (Molecularly Assembled Robust Superhydrophobic Shell)—for producing superhydrophobic fabrics with stable mechanical performance under harsh conditions.

The findings were published in Nature Communications on March 20.

Traditional superhydrophobic fabrics are usually prepared using expensive nano-fillers and toxic chemical reagents, while commercial waterproof textiles largely depend on fluorochemicals—now facing an impending ban in multiple countries from 2026. Additionally, the superhydrophobic layer on the fabric surface is often fragile—easily worn off during friction, washing, or exposure to extreme conditions, leading to rapid loss of superhydrophobic performance.

To address these limitations, the researchers designed the MARS strategy to directly construct a robust superhydrophobic shell on individual fibers. The treatment achieves superhydrophobicity at the single-fiber level and is compatible with a variety of natural and synthetic fibers. The hydrophobic performance is retained even after the treated fibers are further processed into knitted or woven fabrics.

The researchers systematically evaluated the stability of MARS-treated fabrics under harsh conditions. Under prolonged raindrop impact and high-speed droplet impact, the fabric remained superhydrophobic. In standard abrasion tests (e.g., Martindale and Taber tests), MARS-treated fabrics remained superhydrophobic even after tens of thousands of abrasion cycles. Durability was further validated through simulated wear conditions, including friction from backpack straps, stretching cycles, brushing, tape peeling, and activities such as running and walking.

Furthermore, the superhydrophobic fabric shows broad environmental tolerance. It can maintain stable superhydrophobic performance under extreme conditions, including high temperatures (160 °C under steam) and low temperatures (-196 °C under liquid N₂).

Experimental results also confirmed that the modification process does not damage the fabric's inherent properties, such as breathability, moisture permeability, softness, and tensile strength, ensuring good wearing comfort. This balance between superhydrophobic functionality and wearability is a key breakthrough for the practical application of superhydrophobic fabrics.

The MARS technology paves the way for next-generation waterproof fabrics that combine sustainability and high performance in outdoor, protective, medical, and industrial applications.

This work was supported by the National Natural Science Foundation of China and the Young Elite Scientists Sponsorship Program of the China Association for Science and Technology.

Schematic illustration of the MARS technique. (Image by DONG's Group)