NanoLayr: one of the top nanofibre manufacturers

Nanofibres are one-dimensional nanomaterials of fiber shape with a diameter in the range of tens to hundreds of nanometers. Nanofibers have unique properties in terms of high surface area–to–volume ratio, interconnected nanoporosity, and high mass transport properties.

NanoLayr manufactures quality functional nanofibre textiles on a huge scale. Having perfected its nanofibre manufacturing solution, NanoLayr can supply any size business and put its product into existing production lines. For the world’s most advanced air filter or mask, or longer life, higher performing composites, or revolutionary skincare, or the world’s quietest automobiles or office spaces, the Layr nanofibre platforms are ready and waiting. A NanoLayr product could just be the secret ingredient in the next commercial success.

The polymers NanoLayr has developed so far include Polylactic Acid (PLA), Cellulose Acetate, Polycaprolactone (PCL), Nylon (various), Polyesters (various), Polyethylene terephthalate (PET), Polyvinylidene fluoride (PVDF), Polyethylene oxide/glycol (PEO/PEG), Polyvinyl Alcohol (PVOH), Polyhydroxybutyrate (PHB), Polyacrylonitrile (PAN), Polyurethane (PU), Polyvinyl butyral (PVB), Polyamic acid (PAA), Poly(methyl methacrylate) (PMMA), Polycarbonate Urethane (PCU), Collagen, Lignin, Thermoplastic elastomers (TPE), and so many more.

State-of-the-art services provided by NanoLayr

R&D services: NanoLayr’s R&D services cover literature review, concept development, feasibility studies, prototyping and production scale-up, a full TRL1-9 platform. From initial concept to market, NanoLayr’s world-leading electrospinning teams in New Zealand and the United Kingdom work with the clients to support and develop bespoke nanofibre solutions for the specific application requirements. Utilizing a refined development platform, the organization will guide and develop the client’s material needs through to large scale supply, an all-in-one pain-free solution to nanofibre product development.

DermaLayr: DermaLayr delivers collagen and active ingredients 1.8mm into the dermal skin layers in 15mins. It delivers collagen and active ingredients up to 2.5mm into the dermal layers over 50mins. It’s also comparable only to invasive needle treatments. NanoLayr have developed DermaLayr for use in modern skincare products. Produced using a proprietary production method – Sonic Electrospinning Technology, DermaLayr is an ultra-thin non-woven web of kilometer long collagen nanofibres. The technical features this specific service entail:

• the fastest non-invasive dermal delivery system in the world
• sustainably sourced premium type 1 marine collagen
• water-soluble, dissolves into wet skin
• delivers collagen and active ingredients 1.8mm into the dermal skin layers in 15mins
• delivers collagen and active ingredients up to 2.5mm into the dermal layers over 50mins
• potential to carry the client’s own ingredients like bioactive
• instant absorption

FilterLayr: NanoLayr’s latest innovation, FilterLayr Eco filter media, is made up of a patent-pending formulation, containing natural manuka oil that provides bactericidal and virucidal properties for air filtration products (e.g. face mask and/or respirator). Made from industrially compostable raw materials, it meets international standards whilst also having extremely high breathability. FilterLayr is electrospun nanofibre which can be infused with active additives designed to trap and neutralize even the smallest airborne particles, while still allowing excellent airflow rates. FilterLayrs are created using the company’s proprietary ‘sonic’ electrospinning method, which allows the organization to include functional additives to the chemistry of the nanofibre. It also guarantees the quality and high filter efficiency of the nanofibre. The technical features this specific service entail:

• made out of highly advanced electro-spun nanofibre material
• Incredibly high surface area – 1m2 of FilterLayr contains 7.8m2 of surface area and 8,300km of nanofibre.
• Wide ranging functionality is available, including antibacterial and antiviral properties.
• rolled goods ready to ship and shape
• commercially viable

SonoLayr: This nanofibre is specifically designed to enhance the acoustic performance of any sound-control product. It has an incredibly high surface area but very little thickness, so improves the sound absorption levels of any baffling, furniture or other acoustic panel it is added to, while adding negligible thickness or weight to the product. SonoLayrs are created using NanoLayr’s proprietary ‘sonic’ electrospinning method, which guarantees quality and efficacy of the nanofibre. SonoLayr redefines acoustic attenuation. Air molecules in the porous nanofibre material vibrate and rub against the nanofibres, leading to the conversion of sound energy to heat energy which is then dissipated. The technical features this specific service entail:

• ultra-lightweight
• incredibly high surface area – 1m2 of SonoLayr contains between 31- 38m2 of surface area and contains between 37,000 – 44,000km of nanofibre
• tunable for performance at specific frequencies
• rolled and ready to cut
• performs best on sounds between 800-5000hz – aligning well to human hearing ranges typical for indoor and outdoor noise

XantuLayr: XantuLayr is a unique interlaminar reinforcement veil consisting of tough thermoplastic nanofibres which have the ability to greatly enhance the performance of composite materials. NanoLayr have developed XantuLayr, the world’s first commercially available interleaving nanofibre veil, for use in fibre reinforced thermoset polymer composite materials. Produced using a proprietary production method (Sonic Electrospinning Technology), XantuLayr is an ultra-thin non-woven web consisting of kilometer long thermoplastic nanofibres, each one being about 500x thinner than a human hair. The technical features this specific service entail:

• Thermoplastic nanofibre interleaving veil on silicone release paper.
• highly porous – allows the resin to penetrate the veil
• compatible with epoxy and polyester resin systems
• available in areal weights of 1.5gsm, 3gsm & 4.5gsm
• as9100 aerospace certified
• 1m²at 1.5gsm contains 23m2 of surface area and 32,000km of nanofibre
• 1m²at 3gsm contains 46m2 of surface area and 64,000km of nanofibre
• 1m²at 4.5gsm contains 69m2 of surface area and 96,000km of nanofibre

Meet the leader behind the success of NanoLayr

Andrew Turnbull, Chairman

Andrew trained as a Chemical and Process Engineer and then spent 12 years in Biotech and Pharmaceutical Industries in the UK and Europe before returning to NZ. He has spent the last 15 years working with deep tech growth companies and technologies to help them scale and grow. His experiences have spanned manufacturing, engineering, business development and R&D across a diverse set of industries.

“From chemists to production engineers, everyone is passionate about the creation of world-class functional fabric to improve the quality of lives for end-user.”