The COVID-19 pandemic presents a unique challenge to the healthcare community due to the high infectivity rate and need for effective personal protective equipment. Zinc oxide nanoparticles have shown promising antimicrobial properties and are recognized as a safe additive in many food and cosmetic products. This work presents a novel nanocomposite synthesis approach, which allows zinc oxide nanoparticles to be grown within textile and face mask materials, including melt-blown polypropylene and nylon-cotton. The resulting nanocomposite achieves greater than 3 log10 reduction (≥ 99.9%) in coronavirus titer within a contact time of 10 min, by disintegrating the viral envelope. The new nanocomposite textile retains activity even after 100 laundry cycles and has been dermatologist tested as non-irritant and hypoallergenic. Various face mask designs were tested to improve filtration efficiency and breathability while offering antiviral protection, with Claros’ design reporting higher filtration efficiency than surgical masks (> 50%) for particles ranged 200 nm to 5 µm in size.

Healthcare associated infections cause millions of hospitalizations and cost billions of dollars every year. A potential solution to address this problem is to develop antimicrobial textile for healthcare fabrics (hospital bedding, gowns, lab coats, etc.). Metal nanoparticle-coated textile has been proven to possess antimicrobial properties but have not been adopted by healthcare facilities due to risks of leaching and subsequent loss of function, toxicity, and environmental pollution. This work presents the development and testing of antimicrobial zinc nanocomposite textiles, fabricated using a novel Crescoating process. In this process, zinc nanoparticles are grown in situ within the bulk of different natural and synthetic fabrics to form safe and durable nanocomposites. The zinc nanocomposite textiles show unprecedented microbial reduction of 99.99% (4 log10) to 99.9999% (6 log10) within 24 h on the most common Gram-positive and Gram-negative bacteria, and fungal pathogens. Furthermore, the antimicrobial activity remains intact even after 100 laundry cycles, demonstrating the high longevity and durability of the textile. Independent dermatological evaluation confirmed that the novel textile is non-irritating and hypoallergenic.