Abstract
Developing robust water-repellent textiles is critical for outdoor, protective, and industrial applications. However, achieving long-lasting water repellency under mechanical stress remains a significant challenge. Conventional approaches typically rely on nanoparticle assemblies or PFAS-based finishes, which often detach or degrade when subjected to abrasion or harsh conditions. Here, we demonstrate a molecularly assembled robust superhydrophobic shell (MARS) technique that directly constructs an ordered, covalently bonded, fluorine-free silica shell on individual yarn fibers via a one-step process. MARS eliminates the need for discrete nanoparticles or fluorinated chemistries and is compatible with a wide range of natural and synthetic fibers. This fiber-level treatment maintains superhydrophobicity even after the fibers are woven or knitted into finished textiles, while preserving breathability and mechanical resilience. MARS combines biomimetic inspiration with practical, scalable fabrication to meet urgent performance needs. Unlike conventional coatings that progressively degrade, the permanently bonded MARS coating endures intensive abrasion, high-velocity water impacts, steam exposure, and extreme temperature cycles. By addressing key challenges such as PFAS restrictions and the fragility of traditional coatings, the MARS method paves the way for next-generation water-repellent fabrics that balance sustainability and high performance across outdoor, protective, medical, and industrial applications.
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All relevant data supporting the key findings of this study are available within the article and its Supplementary Information or from the corresponding author upon reasonable request. Source data are provided with this paper.
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Acknowledgements
We thank Dr. Shihui Zhu (TIPC) for initiating the request that our team prepare non-PFAS superhydrophobic cloth samples for the Science and Technology Festival at the Chinese Academy of Sciences since 2020. MARS-based superhydrophobic garments have been used for public engagement with primary and secondary school students. The MARS modified cloth was thus prepared and has been shown to visitors with harsh water-splash tests more than 104times, and was featured in multiple science communication activities, such as the Science Open Class in 2022 (https://live.kepu.net.cn/live/index?id=35FE51D14DB436633914B1) and 2024 Chinese Academy of Sciences Science Experiment Showcase, involving Dr. Dong and Zhuoxing Liu., Tao Shen, Jie Ma, Jia Peng, Kexin Zhao. This work has been continuously refined in response to industrial demands. We acknowledge the support from industrial partners and the support from the Shunyi District Government of Beijing and the Beijing Institute of Future Science and Technology on Bioinspired Interface. We are deeply appreciative of S. Hong and T. Cai from China Strait Talent Market and the Shishi government for their generous assistance throughout the research, especially in the textile weaving and cloth production processes. We are grateful to L. Tian for technical assistance with Environmental SEM; Dr. W. Zhang of LINING Co. Ltd. for providing yarns and shoe vamps; and Dr. Z. Xiong, Y. Liu, and H. Zhi of ANTA Sports Co. Ltd. for supplying yarns and fabrics. We also thank Prof. J. Su (Jiangnan University) for support with knitting, and Dr. S. Hou and Dr. J. Zhang (KRUSS, China) for conducting the fiber contact-angle measurements. We acknowledge Darong Textile Instrument Co., Ltd. for providing standard textile testing equipment, Dr. J. Xiang for technical support, and Dr. H. Ding (Suzhou Niumag Analytical Instrument) for assistance with low-field NMR measurements. We express our sincere gratitude to Dr. T. Cai, Dr. F. Zheng, and Engineer Cai from the China Textile Academy Institute for their expert guidance during performance testing. We further express our sincere gratitude to Chairman Y. Chen from Wujiang Hanta Textile Finishing Co., Ltd., for providing the final products. We thank the 17 instructors of Group 3 of the 9th CAS Young and Middle-Aged Talent Training Program for testing the textile T-shirts and providing valuable feedback throughout September 2025. We acknowledge project funding from the National Natural Science Foundation (22122508 and 52173293 to ZD) and the Young Elite Scientists Sponsorship Program of the China Association for Science and Technology (ZD).
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Z.D. conceived and designed the project, supervising all aspects. L.Z. and D.H. were responsible for material preparation and testing characterization, assisted by K.Z., S.L., Z.Z., and L.W. L.Z., J.M., and D.H. analyzed the experimental data. Z.L., D.H., and Z.D. wrote the original manuscript. L.W. and Z.D. supervised the work, offered project support, and revised the manuscript. All authors participated in the discussion.
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The MARS superhydrophobic fabric preparation method is covered by three pending CNIPA patents: CN 202610186197.5 (2026.02.09), CN 202610194657.9 (2026.02.11) and CN 202610208747.9 (2026.02.13). Applicants: Beijing Institute of Future Science and Technology on Bioinspired Interface. Inventors Zhichao Dong, Zhuoxing Liu and Dezhao Hao are also paper authors. The authors declare that they have no competing interests.
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Liu, Z., Zhao, K., Ma, J. et al. One-step fabrication of superhydrophobic fabrics with stable mechanical performance in harsh conditions. Nat Commun (2026). https://doi.org/10.1038/s41467-026-70857-7
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DOI: https://doi.org/10.1038/s41467-026-70857-7
