This study investigates whether CO2 laser distressing can create acceptable distressed aesthetics on multiple knitted fabric structures while maintaining durability after washing. The primary aim was to evaluate the performance of CO2 laser technology under laundering conditions, with the long-term objective of establishing it as a standard, environmentally sustainable process in garment manufacturing. Thirteen knitted fabric samples were subjected to CO2 laser treatment followed by washing tests to assess changes in appearance, structural integrity, and shrinkage behavior. The results indicate that most knit structures did not retain satisfactory distressed effects after laundering. However, French terry fabric emerged as the only substrate that maintained a controlled distressed appearance with acceptable shrinkage and structural integrity. The findings position CO2 laser finishing as a more sustainable alternative to conventional distressing processes such as sandblasting and acid washing, which are associated with significant environmental and health hazards. While CO2 laser technology demonstrates strong potential for sustainable textile production and fashion design, challenges remain in ensuring garment durability and long-term aesthetic retention, as demanded by consumers. Given that the fashion industry contributes approximately 10% of global carbon emissions, adopting cleaner technologies such as CO2 laser processing could significantly reduce environmental impact while supporting innovation and new employment opportunities in sustainable manufacturing.
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