
A GUIDE TO POLYESTER, COTTON, AND BLENDED FABRICS
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Fabric choices matter. The composition of the garment is arguably the most important factor when it comes to selling apparel. Each fabric has different properties. Cotton, polyester, or blended fabrics: which is the best choice for you?
Read our guide to learn the differences between cotton, polyester, and blended fabrics when selecting materials.
1. What is Fiber?
Fibers are the fundamental components used to create fabrics. Fibers are spun into yarns, which are then woven, knitted, or bonded to produce various kinds of fabric. They can be categorized into two main types:
- Natural Fibers: Derived from plants (like cotton or flax) and animals (like wool or silk), these fibers are known for their comfort and eco-friendliness.
- Synthetic Fibers: Man-made using chemical processes, examples include polyester, nylon, and acrylic. These fibers often offer durability and resistance to environmental factors.
2. What is Fabric?
Fabric refers to the material made by interlacing fibers in a systematic manner. It serves as the foundation for countless applications, from clothing and upholstery to industrial uses. Fabrics can be made from fibers in a variety of ways. The two most typical ones are:
- Weaving: Two sets of yarn are crossed over and beneath one another in a crisscross pattern to make fabrics. Woven textiles with this crossing pattern are warm, stiff, and stretch-resistant.
- Knitting: By tying a single yarn to a needle, creating loops, and joining the loops, knitting produces textiles. Knit fabric is more stretchy, cooler, and more wrinkle-resistant than woven fabric.
3. Cotton vs Polyester: A comparison
Polyester and cotton are popular materials, widely used in the garment industry. With diverse colors and great applications, both of these fabrics make expensive fashion items. Each has its own distinct qualities and uses. What is the main difference between cotton and polyester? In a nutshell, their production process and qualities are what distinguish them. Which is superior, cotton or polyester? Everything will depend on your needs and the kind of product you want to make.
4. What are the properties of Polyester Fabric?
Polyester is a synthetic fiber fabric, created by melting and pressing into molds. Its solid, non-hollow structure makes the fabric durable and retains its shape well. Although polyester fibers do not absorb sweat, they are water-resistant, moisture-wicking, UV-resistant, and have antibacterial and anti-mold properties. This makes them an excellent choice for manufacturing sportswear that requires high durability and resistance to environmental factors.
Pros:
- Durability: Polyester is exceptionally strong and resistant to stretching, shrinking, and abrasion.
- Lightweight and Flexible: Despite its strength, polyester is lightweight and flexible, providing comfort for wearers. Excellent for activewear clothing and demanding outdoor activities.
- Moisture Wicking: Polyester has low moisture absorbency, allowing it to wick sweat away from the skin to the fabric’s surface, where it evaporates quickly. This makes it a favorite for activewear and outdoor apparel.
- Quick Drying: Thanks to its low absorbency, polyester dries much faster than natural fibers like cotton.
Cons:
- Low Breathability: Polyester is less breathable than natural fibers, which can lead to discomfort in warm and humid conditions.
- Static Electricity: The synthetic nature of polyester often leads to static build-up, which can cause clinginess and discomfort.
- Non-biodegradable: As a chemically synthetic fabric, polyester has low biodegradability, taking 20 to 200 years to fully decompose.
5. The various uses of polyester
Polyester fabric is highly valued for its durability and wrinkle resistance. Due to polyester’s highly functional fiber, it’s well suited for making a vast array of garments.
- Clothing: Activewear, outerwear, and everyday garments.
- Home Textiles: Curtains, upholstery, and bed linens.
- Industrial Applications: Conveyor belts, ropes, and safety gear.
- Outdoor Gear: Tents, backpacks, and weather-resistant apparel.
6. What are the properties of cotton?
Cotton fabric is derived from the natural cotton plant. Cotton fibers are harvested from the cotton bolls and subsequently utilized to craft fabric products. In the market, this material is highly popular and widely used in various manufacturing and textile industries. It is the most popular choice because of its softness, breathability, and durability.
Pros:
- Softness: Cotton is known for its softness and breathability, making it comfortable to wear against the skin, especially in hot weather.
- Durability: Cotton fibers are chemically treated before being woven into fabric, resulting in long-lasting durability without worrying about fabric deterioration.
- Biodegradability: Cotton is a natural and biodegradable fiber that can decompose naturally within a few months.
- Non-irritating: Made from natural materials, cotton is very safe for the skin and does not cause irritation. Therefore, it is often used for custom underwear, socks, and other garments worn close to the skin.
Cons:
- Wrinkles easily: Cotton is prone to wrinkles and may lose its shape after washing, requiring special care to preserve its original form.
- Moisture Retention: Cotton absorbs moisture effectively but dries slowly, which can cause discomfort in humid or wet conditions.
- Flammable: Cotton catches fire easily and burns rapidly.
7. Four different varieties of cotton
Cotton is commercially grown worldwide. Due to its outstanding characteristics, cotton has been used to create a wide variety of products for centuries.
These are the most common:
Pima cotton
Pima cotton is an ultra-soft fabric that incorporates long cotton fibers. Most types of cotton use relatively short fibers, but Pima is one of a few kinds of cotton that are considered to be extra-long staple (ELS) cotton. Thanks to its long fiber structure, pima cotton overcomes some of the disadvantages of regular cotton, such as being more durable, wrinkle-resistant, and fade-resistant. It is an expensive, high-quality cotton.
Egyptian cotton
Similar to Pima cotton, they both share premium characteristics – extra-long fibers that make it soft, smooth, and durable. The difference lies in where they are grown. Pima cotton is primarily grown in the United States, Egyptian cotton in the Nile River Valley.
Upland cotton
Upland cotton is the main supplier of cotton fibres for clothing and one of the most cultivated crops worldwide. Although it’s not as soft as Pima or Egyptian, it’s an excellent fiber for everyday products. It is an affordable option.
Acala cotton
A special variety of cotton produced only in California, in the ideal climate of the San Joaquin Valley. One of the finest quality Upland cottons in the world. However, due to irrigation requirements, Acala tends to be more expensive than other American-grown Upland cottons.
8. The versatile uses of cotton
The applications of cotton are vast due to its versatility. Common uses include:
- Apparel: Cotton is widely used in clothing like t-shirts, jeans, dresses, and underwear.
- Home textiles: It's used in towels, bed sheets, and blankets for its durability and comfort.
- Medical applications: Cotton is used in bandages, gauze, and other medical supplies due to its strength and absorbency.
- Accessories: Bags, scarves, and face masks leverage cotton’s lightweight and breathable qualities.
9. What are blended fabrics?
Blended fabrics combine natural and synthetic fibers to leverage the best qualities of each. For example, a cotton-polyester blend might offer the softness and absorbency of cotton with the durability and wrinkle resistance of polyester.
If you can’t choose between cotton or polyester, let’s look at their blends and see whether one of these would better fit your brand and needs.
50% Cotton / 50% polyester blend
Combines the softness and breathability of cotton with the durability and wrinkle resistance of polyester. Commonly used for activewear and casual wear, offering a balance of comfort and practicality.
65% Cotton / 35% polyester blend
Retains the natural feel of cotton while improving durability and reducing shrinkage. Ideal for uniforms, workwear, and home textiles that require easy maintenance.
65% Polyester / 35% cotton blend
This is the most popular blended fabric for clothing, such as t-shirts. Polyester adds shrink resistance, while the cotton content lowers the cost. This blend is popular for sportswear.
10. Key takeaways
In the world of fiber, neither is better. The fact is that each of them has pros and cons. Neither of them will ever replace the other. Polyester offers strength, durability, and quick-drying properties, while cotton provides softness, comfort, and breathability. Blended fabrics combine the best of both worlds, offering a balance of properties. Understanding the characteristics of different fabrics can help you make the most informed choices.