Curbside-recyclable Products from Mono-material Polyethylene Fabrics With Polyethylene 3D Printed Features and Methods Thereof

A polyethylene (PE)-based fully-recyclable textile material and product formed by three-dimensionally printing PE structures onto a polyethylene textile is provided. The textile material can include one or more PE filaments being directly deposited onto a PE fabric via an FDM printing process to form a mono-material. The deposition of structures onto the PE fabric, which can form the substrate of the textile, can be used to enable changes to the mechanical properties of the fabric and/or create novel design aesthetics. Moreover, this material can be characterized by its ability to be thermally recycled, from which new PE-based products and materials may be manufactured. For example, the PE-based fully­-recyclable textile material can be formed into a PE recyclate that can be melted and re-pelletized for formation of alter­native PE-based fully recyclable textile materials. The PE-­based fully recyclable textile material can be used in foot­wear and other wearable applications, as well as spacesuits, helmets, bulletproof vests, sweat-proof garments, racing suits, and so forth.