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Plasma-Assisted Surface Engineering of Textiles and Polymers for Improved Flame Retardancy: A Comprehensive Review

Shreyasi Nandy, T V Sreekumar, Abhishek P M, Shubham Shinde (BTRA, Mumbai), Neha Mehra(VJTI)

BTRA Scan – Vol. LV No.1 , January, 2026, Page no. 20-34 DOI: 70225/943046krpkfq

Keywords: Plasma treatment, Flame retardancy, Surface modification, Dielectric barrier discharge (DBD).

Abstract

Flame-retardant materials are increasingly critical across textiles, polymers, electronics, and construction, yet conventional chemical finishing often compromises fabric integrity, durability, and environmental safety. Plasma-assisted surface modification has emerged as a sustainable alternative, selectively functionalizing the outer nanolayers of substrates without altering bulk properties. This review highlights the principles and types of plasma, particularly non-thermal methods such as dielectric barrier discharge (DBD), corona, and glow discharge, and examines their role in enhancing adhesion, durability, and performance of flame-retardant coatings on cotton, polyester, polypropylene, and polyamide. Compared with traditional chemical, sol–gel, or inherently flame-resistant approaches, plasma treatment offers superior surface specificity, reduced chemical usage, and ecofriendliness. Despite challenges in cost and process optimization, plasma-assisted strategies represent a versatile route for nextgeneration, durable, and environmentally responsible flame-retardant materials.

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