Abstract: Aspects herein are directed to systems, methods, and articles for producing a patterned film and using the patterned film to form a pattern of discrete overlay film structures on a substrate material. A uniform thickness of a film material is deposited on to a first surface of a run of carrier sheets, where each carrier sheet includes one or more holes extending there through. A first carrier sheet is extracted from the run of carrier sheets, and a second surface of the carrier sheet is positioned on a substrate material. Heat and/or pressure is applied to the film material to cause the film material to transfer to the substrate material through the one or more holes in the carrier sheet forming a pattern of discrete overlay film structures on the substrate material. The carrier sheet along with remaining portions of the film material is removed from the substrate material.

Abstract: Aspects herein are directed to a composite nonwoven textile suitable for use in apparel and other articles that are resistant to pilling. The composite nonwoven textile may be finished by one or more of applying a chemical binder to a first face of the composite nonwoven textile and forming thermal bonding sites. The chemical binder and the thermal bonding sites help to secure fiber terminal ends and minimize the formation of pills.

Abstract: Aspects herein are directed to a recyclable, asymmetrical-faced composite nonwoven textile suitable for use in apparel and other articles and methods of making the same. In example aspects, the asymmetrical-faced composite nonwoven textile includes a first face formed, at least in part from a first entangled web of fibers and an opposite second face formed, at least in part from a second entangled web of fibers. When incorporated into an article of apparel, the first face forms an outer-facing surface of the article of apparel, and the second face forms an inner-facing surface of the article of apparel. The first face includes features making it suitable to form the outer-facing surface such as resistance to abrasion, and the second face includes features making it suitable to form an inner-facing surface such as a soft hand.

Abstract: Aspects herein are directed to a printed composite nonwoven textile suitable for use in apparel and other articles and methods of making the same. In example aspects, the printed nonwoven textile includes an interior layer with a printed component that is visible on a first facing side of the printed nonwoven textile that is formed, at least in part, from a first entangled web of fibers, fibers of the interior layer, and/or a colored substance the forms the printed component. When incorporated into an article of apparel, the first facing side is an outer-facing surface of the article of apparel that includes the printed component.

Abstract: Aspects herein are directed to a recyclable, asymmetrical-faced composite nonwoven textile suitable for use in apparel and other articles and methods of making the same. In example aspects, the asymmetrical-faced composite nonwoven textile includes a first face formed, at least in part from a first entangled web of fibers and an opposite second face formed, at least in part from a second entangled web of fibers. When incorporated into an article of apparel, the first face forms an outer-facing surface of the article of apparel, and the second face forms an inner-facing surface of the article of apparel. The first face includes features making it suitable to form the outer-facing surface such as resistance to abrasion, and the second face includes features making it suitable to form an inner-facing surface such as a soft hand.