Velcro: from pesky burrs to fasteners
Velcro was inspired by burrs, which are seeds or dry fruits that have small spikes on them.
In the 1940s, George de Mestral took his dog, Milka, for a walk in the Alps. Burdock seeds (burrs) clung to his socks, coat and to Milka's fur. He wondered why this happened and observed the seeds through a microscope.
He found that there were tons of microscopic hooks on the tips of these burr spikes. When looped material comes into contact with a burr, the hooks attach themselves to it. George had an idea to create a new fastener from his findings. Now he needed to figure out what materials to use and how to form loops and hooks which could be manufactured.
He experimented with materials for about three years. He tried weaving and bending natural material like cotton and wool, but the bond was weak. He realized that, unlike cotton and wool, burr hooks are somewhat taut with a smooth surface. So he began experimenting with synthetic materials like nylon for several more years. He wove nylon threads to create loops and made hooks by heating strands of nylon under tension, a process called heat-setting.
His invention worked incredibly well, leading to a patent and a company, Velcro IP Holdings, LLC.
George originally tried to use Velcro as a clothing fastener to replace buttons and zippers, but it didn't catch on. Not until NASA needed to fasten astronaut suits and equipment for Apollo 11. Velcro was the ideal choice over buttons and zippers because buttons rely on gravity and zippers are difficult to use with gloves on.
NASA's use cases opened doors for Velcro where its applications diversified rapidly. It was used on military gear, straps and slings, children's footwear, bags, backpacks, protective gear and many more products. It's so ubiquitous that many people refer to all similar "hook and loop" fasteners as Velcro, like how the trade name Kleenex can be used in place of “tissue.”
Today, Velcro is typically made entirely of nylon, although polyester and Nomex, a synthetic fiber from DuPont, are used too.
Despite it not being made from sustainable materials, Velcro is a biomimicry design. Inspiration can strike from any corner, even hidden from within pesky burrs.
