Startup unveils recyclable stretch nylon without elastane

Return to Vendor, a circular materials startup based in New York, has announced a major breakthrough for the textile industry, a fully stretchable nylon that is 100 percent recycled and recyclable, achieved without the use of elastane or spandex. Co-founder Adam Baruchowitz compared the development to a “moon landing” moment for textile recycling.

The innovation addresses one of the biggest obstacles in textile-to-textile recycling, elastane. Baruchowitz noted that elastane has long been cited by recyclers as a major barrier to large-scale textile recycling. High levels of spandex in garments can damage equipment, limiting how such materials can be processed and slowing recycling systems overall.

The company’s approach is based on advanced material science. Using recycled nylon-6 sourced from discarded fishing nets and old carpets, Return to Vendor altered the molecular structure of nylon using green chemistry methods. This allows the material to stretch and recover in a way similar to elastane, without the need for added synthetic stretch fibers or solvents.

According to Gangadhar Jogikalmath, the company’s lead scientist, adjusting how nylon molecules arrange themselves makes the fiber flexible under stress while allowing it to return to its original shape. This transforms traditionally rigid nylon into a material suitable for stretch applications such as activewear.

Looking ahead, Return to Vendor plans to develop a full range of performance specifications to meet industry needs, including durability, heat resistance, wash performance and dyeability. The company also sees potential for closed-loop recycling systems that align with extended producer responsibility requirements and reduce microplastic shedding.