Projects

Selected projects across product development & textile research

Click any project to view details and add photos, PDFs, or external links.

Development of Nylon 66 Coated Motorcycle Jacket (Comprehensive Design Project)

Product Development Specialist

Development of Nylon 66 Coated Motorcycle Jacket (Comprehensive Design Project)

Developed a lightweight, durable, and cost-effective motorcycle jacket for improved rider safety, bridging the gap between heavy protective gear and lightweight jackets with limited protection. Built from Nylon 66 basket weave fabric coated with Styrene Butadiene Rubber (SBR) in a four-layer composite structure with two Nylon 66 layers and two SBR coating layers, improving abrasion resistance, tear strength, and durability. The technical design includes shoulder, elbow, and back reinforcement panels, a stand collar with snap closure, center front zipper, side welt zipper pockets, adjustable cuff and waist tabs, reinforced seams, bonded nylon thread, and protective topstitching. The result balances safety, comfort, affordability, and durability in a clean fitted rider silhouette suitable for commercial use, with performance validated through abrasion, impact, tear, bursting strength, and impact-cut resistance testing.

Technical DesignComposite MaterialsNylon 66SBR Coating+2

Development of Upcycled Denim Jacket (Ongoing Sustainable Design Project)

Sustainable Design Lead

Development of Upcycled Denim Jacket (Ongoing Sustainable Design Project)

An ongoing sustainable design project initiated after observing large quantities of donated used denim garments remaining unsold during my volunteer work at Wirral Hospice St John's in the UK. The aim is to upcycle unsold denim jeans into a sustainable, affordable, and commercially viable denim jacket for the Sri Lankan market. I developed a prototype in partnership with MUTA – Moratuwa University Textile Association and Zeera Holdings, using approximately 78% of fabric from each used denim garment, with planned collaboration with Wirral Hospice St John's to create a circular fashion model. Compared with a regular denim jacket priced around LKR 18,000, the upcycled version is planned at approximately LKR 8,000, targeting a realistic gross profit margin of 25%–35% while reducing denim waste and promoting circular fashion.

UpcyclingCircular FashionSustainable DesignDenim+2

Reducing Material Wastage in Cut Store and Issuing Section – Internship Project (Calzedonia Group – Omega Line Vavuniya Apparels Ltd.)

Textile Engineer Intern

Reducing Material Wastage in Cut Store and Issuing Section – Internship Project (Calzedonia Group – Omega Line Vavuniya Apparels Ltd.)

Internship project investigating how cut store and issuing section inefficiencies were contributing to material wastage, missing bundles, poor space utilisation, and production downtime within the plant. Using structured analysis and process improvement tools such as 5S, Poka-Yoke, Kaizen, and root cause analysis, I developed practical methods to improve stock visibility, reduce location errors, identify old stock quickly, and strengthen issuing accuracy. The project identified cut store and issuing as major contributors to downtime, accounting for 41.2% of total plant downtime. Improvements in organisation, stock control, and visual tracking helped reduce waste, improve material flow, increase plant productivity by 2%, and improve cutting efficiency by 6%.

5SPoka-YokeKaizenRoot Cause Analysis+2

Researcher

Polyester Woven Fabric Dyeing Research

Researched the effect of yarn dyeing on 100% polyester woven fabrics, identifying changes in elongation and fabric flexibility.

Textile EngineeringPolyester FabricYarn DyeingFabric Properties+1

Researcher

Woven Label Research Project

Investigated the effect of weft yarn colour on the properties of woven labels, working with industry partners to improve durability, production efficiency, and product quality.

Textile TestingWoven LabelsResearchProduct Quality+1