How Does polyester spandex blend Work?
Is polyester stretchy? All you need to know about polyester - Printify
Polyester is known for its durability, but is polyester stretchy? While 100% polyester lacks natural stretch, certain manufacturing techniques and blends help add flexibility.
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Let’s explore everything about polyester, from its stretchability to its production process, and more.
Key takeaways
- Polyester is a synthetic material known for its durability and versatility.
- The stretchability of polyester fabric depends on the blend and type of weave used in production.
- Manufacturers blend polyester with elastic fabrics like spandex or elastane to enhance comfort and fit.
- Polyester fabric is suitable to use in Print on Demand for direct-to-garment and all-over prints.
What is polyester?
Polyester is a synthetic material made from polyethylene terephthalate (PET) fibers, the same plastic found in water bottles.
Known for its cost-effectiveness, durability, and versatility, polyester is prevalent in the fashion industry, from outerwear to activewear.
Its durability also makes it ideal for household and industrial products like ropes and air filters.
The pros and cons of polyester
Pros:
- Durability – Polyester is known for its long-lasting strength, making it ideal for clothing, home goods, and industrial products.
- Wrinkle-resistant – One of the key advantages of polyester is its ability to maintain a smooth, wrinkle-free look without constant ironing.
- Moisture-wicking – Unlike natural fabrics such as cotton, polyester quickly draws moisture away from the skin, keeping you dry during physical activities.
- Shrink and stretch resistance – Polyester holds its shape well, even after frequent washing and wear.
- Cost-effective – It’s a budget-friendly option for businesses looking to produce durable, high-quality garments.
Cons:
- Breathability – Polyester can feel less breathable than natural fibers, which may cause discomfort in hot climates.
- Texture – Wondering what does polyester feel like? Some people find it less soft compared to cotton or rayon.
- Odor retention – Polyester tends to trap odors, which can be an issue in activewear unless treated for odor resistance.
- Environmental concerns – Polyester is made from petroleum-based materials, raising sustainability concerns despite advancements in recycling techniques.
Is polyester stretchy?
Polyester itself is not inherently stretchy, but it can offer flexibility depending on its weave or blend with elastic fibers.
Knitted polyester and blends with spandex or elastane are go-to options for those looking for a stretchier fabric. This combination provides comfort, movement, and durability – ideal for activewear and fitted garments.
Factors that affect polyester stretchability
There are several factors that affect how stretchy polyester is, including the type of polyester, the weaving method, and the fabric thickness.
Material combinations like a poly-cotton blend offer greater elasticity and comfort, while a plain weave tends to hold its shape and negatively affect the stretchiness of polyester.
Should you size up with 100% polyester?
Since 100% polyester has minimal stretch, we recommend sizing up for a more comfortable fit, especially in form-fitting or tight clothing.
Sizing up supports ease of movement without relying on the fabric’s elasticity, which is often absent in pure polyester garments.
Is polyester more stretchy than cotton?
Pure polyester is less stretchy than cotton. Polyester resists water and maintains its structure, while cotton fibers naturally absorb water and offer slight stretch over time.
However, when blending with elastic fibers like spandex, polyester can become much more flexible than cotton, making it ideal for activewear and fitted garments.
How is polyester made?
Manufacturers produce polyester using two main methods – from raw materials or by recycling plastic.
Both methods create a durable, wrinkle-resistant, and versatile material that is suitable for various products, from t-shirts to pet bandanas.
Let’s take a closer look at each production method.
Polyester made from raw materials
When making polyester from scratch, the main ingredient is ethylene glycol derived from petroleum. Manufacturers react ethylene glycol with dimethyl terephthalate (DMT) or terephthalic acid (TPA) to create a monomer, which undergoes polycondensation to form a polymer.
Next, the producer melts the polymer and extrudes it to form long strands, which are then cut into small PET pellets.
Operators melt and push these pellets through a machine like an oversized sieve to create large threads. Once they cool down, they’re twisted together to make polyester yarn.
Polyester made from recycled plastic
Recycled polyester production begins with collecting used plastic items like bottles. Manufacturers sort these items into clear and dyed plastic, then wash them to remove all contaminants.
After sorting, they clean and dry the plastic thoroughly to make sure it’s free from impurities.
The process continues with melting and extrusions, just like in the previous method.
This recycling technique not only reduces plastic waste but also produces a versatile and durable fabric suitable for various applications, from clothing to home goods.
Different types of polyester blend fabrics
Not all poly-blends are equal, as each has a specific purpose. Some polyester fabrics are meant to be durable and water-resistant. Others need to be stretchy so the wearer can move comfortably.
Combining polyester with both natural and synthetic materials enhances its properties.
Let’s take a closer look at the three most common types of polyester blend fabrics.
Polyester-cotton blends
A polyester-cotton blend is one of the most popular materials in apparel manufacturing. Since this type of knitted polyester fabric is only slightly stretchy, it’s mainly suitable for everyday, low-performance activities.
These polyester-cotton fabrics combine the advantages of polyester, like durability and wrinkle resistance, with cotton’s natural softness and breathability.
Perfect for everyday t-shirts and casual wear, poly-cotton blends are a versatile choice for people looking for comfort without compromising on quality.
If you want your polyester clothing to feature the best of synthetic and natural materials, we recommend poly-cotton blends.
Check out these poly-cotton blends in our Catalog:
Polyester and spandex or elastane blends
Most designers will agree that adding spandex or elastane to polyester greatly enhances its flexibility, making it ideal for garments that demand stretch.
If you’re curious about what does polyester feel like when blended with spandex – it’s smooth, lightweight, and perfect for sportswear, swimwear, and leggings.
While polyester offers moisture-wicking properties to keep the wearer dry, spandex and elastane make sure the fabric retains its shape even after repeated stretching.
Altogether, it’s the perfect combo for cozy days at home or hardcore sessions at the gym.
A little goes a long way with spandex and elastane – you only need a bit to make polyester stretchy. Even adding 10% of elastane can stretch the whole fabric to almost double its size.
Popular polyester-spandex blend products on Printify include:
Triblends
This blended fabric uses three materials – cotton, polyester, and rayon.
Rayon, or viscose, is a semi-synthetic fiber manufactured from both human-made and natural materials, like cellulose derived from wood and other plant fibers.
It’s lightweight, breathable, and moisture-absorbent, but it’s the soft texture and the way it drapes that creates its unique feel.
Combined with the strength of polyester and the comfort of cotton, this fiber trio creates exceptionally comfortable garments.
Browse Printify triblend products like:
Does polyester stretch out or shrink after washing?
Polyester fibers are incredibly durable – regular washing, even in warm water, doesn’t harm 100% polyester fabrics.
It’s essentially plastic, so as long as you keep it away from very high temperatures, it’ll survive heavy use.
However, polyester blends can lose shape over time without proper care, so make sure to follow the washing instructions of your polyester garment.
All of Printify’s indoor and outdoor clothing has detailed care instructions in product descriptions, so your customers can enjoy their garments for many years.
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Printing on polyester or natural fabrics
Both the printing method and fabric you choose as the canvas for your designs significantly impact the color vibrancy and durability.
Synthetic and natural fibers absorb dyes in very distinct ways, affecting how well the artwork holds up over time.
Check out our list of the best t-shirts for printing to make sure your designs last after wash and wear.
Direct-to-garment printing
It’s one of the top printing methods for custom t-shirts and other product types in Print On Demand to bring colorful and detailed designs to life.
These prints generally use water-based inks. Meanwhile, one of the properties of 100% polyester is being water-resistant.
This doesn’t mean that your artwork won’t stick to a polyester garment. The fabric just needs pretreatment to allow the ink to bond effectively.
It’s best to choose light-colored polyester garments for printing to make the design as vibrant as possible.
As an alternative, we have natural fibers that are water-absorbent by default. Cotton is the number one choice for printing with water-based inks as it fully absorbs them.
Sublimation printing
When printing on a polyester material, sublimation is the ideal technique. Unlike natural fibers, polyester absorbs sublimation ink seamlessly, creating vibrant and long-lasting designs. This highlights one of the key benefits of polyester – it bonds well with dye for bright, fade-resistant prints.
What other types of plastic fibers are there?
Synthetic fabrics have changed the game, making it easy to create durable, weatherproof, soft, and elastic garments.
Each fiber offers its own set of advantages, suitable for different types of clothing, home goods, and industrial products.
Let’s look at three of the most popular synthetic fibers and their characteristics.
Nylon
Nylon was the first synthetic fabric to reach mass production. It’s also one of the most versatile materials to make products ranging from apparel and upholstery to seat belts.
This durable fiber makes a very elastic fabric, is resistant to wrinkles, and shows remarkable resilience.
Find high-quality, ready-to-print nylon products in the Printify Catalog:
Acrylic
Acrylic is preferable when the cold weather hits because of its ability to retain heat. The material is a perfect substitute in polyester-wool blends because it’s moisture-resistant, easy to clean, soft, dries fast, and has a wool-like feel.
Thanks to its lightweight and shatter-resistant properties, it’s a popular choice for fall and winter accessories like hats, gloves, and scarves, as well as household items such as cups and storage containers.
Design and sell your own acrylic products with Printify:
Spandex
Apart from being resilient and very elastic – it can stretch more than five times its original size – spandex is extremely lightweight, tear-resistant, and doesn’t pill.
One of the reasons it’s so popular among hosiery manufacturers is that it also doesn’t create that annoying static cling.
Spandex makes polyester fabric stretchy, ideal for apparel that needs to be tight-fitting and comfortable, like activewear, swimwear, compression clothing, and pants.
If you want to learn more, please visit our website polyester spandex blend.
Our Catalog features various items made with spandex, ready for custom-printing:
History of polyester
Polyester was first developed in the early 20th century and quickly became popular in textiles due to its durability, wrinkle resistance, and ease of care. The first polyester fiber, PET, was patented in the early s, kickstarting its widespread use in mass markets.
Over the decades, technological advancements have led to better production methods and blends, making polyester fabric a staple in both fashion and industrial applications.
Today, this synthetic fabric is popular in clothing, home textiles, and various consumer products thanks to its versatility and affordability.
FAQ
Pure polyester isn’t stretchy since the plain weave of this synthetic fabric is designed to maintain shape and resist deformation.
Polyester combined with elastic fibers enhances flexibility and comfort, with knitted polyester fabrics offering the most stretch.
These polyester blends result in a stretchy fabric for a better fit, making them ideal for activewear and fitted garments.
Yes, it offers some degree of polyester stretch, especially when mixed with elastic materials like spandex or elastane.
But although these fibers add flexibility, most garments containing 90% of this synethic material will still have that polyester feel.
It generally feels smooth, lightweight, and has a somewhat synthetic texture compared to natural fibers.
Depending on the specific weave and finish, polyester can range from silky to more structured and crisp.
While it’s generally comfortable to wear, some people might find it less breathable than natural fabrics like cotton. Overall, the feel can vary based on the fabric’s treatment and design.
Polyester fabrics are not highly-flammable – they require more heat and take a while to ignite and than most fabrics. They do, however, start rapidly melting and dripping at very high temperatures.
Polyester starts melting at around 428°F (220°C) and ignites at 809.6°-910.4°F (432°-488°C).
Remember that blended fabrics contain other types of fibers, affecting how quickly the garment catches fire.
Be careful if you encounter burning polyester, as its fumes are toxic to humans and animals.
100% polyester clothes can last a lifetime with proper cared. Clothing manufacturers specifically use polyester to ensure that garments stick to their original form after wash and wear.
Another excellent quality of polyester fabric is that it doesn’t quickly fade in the sun.
Ensure you include care instructions for all your products containing polyester material and remind buyers not to iron, tumble dry, or wash them in hot temperatures.
It can be if it’s manufactured for that purpose. Polyester is made from solid plastic fibers that don’t let air through, so breathability is only achievable with woven polyester fabrics.
Woven fabrics designed for activewear often incorporate moisture-wicking properties that keep the wearer dry and comfortable, making them suitable for sports and hot weather. This is how you get polyester jersey and polyester fleece products.
Each polyester clothing item requires different care because it can feature various ratios of blended fibers. The general guideline for washing 100% polyester is to do it in cold water up to 90°F (30°C) with a detergent and fabric softener specifically made for synthetic fabrics.
We highly recommend against ironing and tumble drying polyester clothing on high heat and instead hanging clothes up to dry to avoid deformation. If you need to speed up the process, put your polyester apparel for a quick spin in the dryer.
Polyester is wrinkle-resistant by default, but it’s better to use steamer instead of a clothes iron if you need to smooth out creases.
Parting words
Are polyester fabrics stretchy? It depends on the type of blends and woven fabrics the product manufacturer uses.
Understanding polyester and its properties will help you make informed choices about which fabric to choose for clothing and other products.
Overall, polyester is an excellent, durable, and versatile fabric to use as a canvas for your designs. With Printify, creating custom polyester garments is easy.
Learn how to start a t-shirt business and start selling high-quality polyester blend garments in just a few clicks.
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What is Spandex Fabric: Properties, How its Made and Where
Fuchsia Foil Metallic Spandex Fabric
What Is Spandex Fabric?
Spandex is a synthetic fabric that is prized for its elasticity. Contrary to popular belief, the term "spandex" is not a brand name, and this term is used to generally refer to polyether-polyurea copolymer fabrics that have been made with a variety of production processes. The terms spandex, Lycra, and elastane are synonymous.
This fabric can stretch to 5-8 times its normal size, and it is commonly used in form-fitting consumer apparel. In most cases, pure spandex isn't used in garments, and instead, small quantities of this fabric are woven into other synthetic, semi-synthetic, or organic fibers.
The base material used to make spandex is polyurethane , which was developed in by IG Farben in Germany. At the end of World War II, hundreds of top German scientists began new careers in the United States, and many of the textile engineers at IG Farben transferred to the DuPont Corporation, which was the era's unquestioned leader in synthetic textile development.
How To Sew Spandex Fabric
Using polyurethane research, DuPont sought to create a new polymer fabric with high elasticity. During the development process, scientists at DuPont referred to this fabric as "spandex;" once this fabric was completed, it was sold under the brand name Lycra, but consumers seemed to prefer to call this material spandex, and it was this term that entered the public lexicon to refer to this synthetic fabric.
Like other polymers, spandex is made from repeating chains of monomers that are held together with an acid. Early in the spandex development process, it was recognized that this material is highly heat-resistant, which means that notoriously heat-sensitive fabrics like nylon and polyester are improved when combined with spandex fabric.
Elastane's stretchiness immediately made it desirable around the world, and the popularity of this fabric persists to this day. It is present in so many types of apparel that practically every consumer owns at least one article of clothing that contains spandex, and it's unlikely that this fabric's popularity will decrease in the near future. Regrettably, however, elastane has a significantly detrimental environmental impact after it is introduced into the consumer market.
How Is Spandex Fabric Made?
Since spandex is a fully synthetic fiber, no organic components are used to make this material. Instead, all of the constituent parts of this fiber are made in a laboratory setting, and they are then combined under specific stimuli to create spandex fabric.
In the years since the invention of elastane, a number of different methods for making this fabric have emerged. Some of these methods are more efficient than others, and, over time, methods like reaction spinning, melt extrusion, and solution wet spinning have mostly been discarded. Nearly 95 percent of the world's spandex is now made with a method called solution dry spinning, and it is this manufacturing process that we will examine in detail.
To begin the spandex fabric production process, a substance called macroglycol is mixed with a diisocyanate monomer under specific heat and pressure. The temperature and pressure conditions must be exact to produce the desired results, and the macroglycol and diisocyanate monomer must also be in a ratio approximate to 1:2.
If the right conditions are applied, a substance called a prepolymer is formed, and this substance is then used in the remainder of the production process. Once it has formed, the prepolymer is exposed to diamine acid, and a chemical reaction called chain extrusion reaction is initiated.
Subrtex 2-Piece Print Jacquard Spandex Fabric Stretch Chair Slipcovers, Gray
The resulting substance is highly viscous, and it must be diluted with a solvent before it can move on to the next step. When it is thin enough to work with, the prepolymer is loaded into a machine called a fiber production cell or a cylindrical spinning cell.
Inside this machine is a device called a spinneret, which has dozens of tiny holes. As the fiber production cell spins, the prepolymer solution is forced through these holes, and it takes on the form of strands of fabric. These strands, however, are still in a liquid state when they emerge from the spinneret, and they are then exposed to heated solvent gas and nitrogen to render them into a solid state.
These solid fibers are then pushed out of the cylindrical spinning cell, and when they are exposed to pressurized air, they form into twisted strands. This compressed air can form strands of many different sizes.
Lastly, the spandex fiber is immersed in a finishing agent consisting of magnesium stearate or a similar chemical. Once it is loaded onto a spool, it is ready to be woven into fabric.
How Is Spandex Fabric Used?
Spandex fabric is used in any consumer or industrial application in which elasticity is desired. Since its inception, this type of fabric has become more and more popular, and these days, it is present in thousands of different types of garments, and it is used by consumers all over the world.
In some cases, pure spandex fabric may be used to make incredibly stretchy or fully form-fitting garments. However, this fabric is relatively expensive, which means that these types of garments are quite costly to the consumers of professionals who use them. Instead, it's much more common to see spandex fabric woven into other types of textiles.
When spandex fabric is added to cotton, for instance, this fabric becomes much more elastic, and spandex can also be used to add elasticity to traditionally rigid fabrics like polyester. Even if small amounts of this fabric are added to other textiles, these fabrics become much stretchier; since spandex can stretch up to eight times its original size, the elasticity imparted by adding this fabric to other textiles can be determined by dividing this stretching potential by the percentage in which it is included in a garment.
Snowflake Rhinestone Mystique Spandex Leotards
The most common application for spandex is in fabrics that are form-fitting. For instance, it is included in many different types of underwear for men and women, and even if it isn't present in the main fabric of an underwear garment, it is almost always present in the waistband. In fact, spandex fabric is found in the waistbands of almost every type of stretch garment.
Spandex is also used in relatively high percentages in cotton and wool socks. Using this fabric in socks helps these garments stay on your feet, and it also facilitates the wearing and removal of socks.
This fabric is highly popular in sportswear. In most types of athletic pursuits, wearing clothes that ride close to the skin is important, so spandex fabric is used in swimwear, bicycling apparel, and types of clothing that are used in competitive team sports.
Lastly, spandex fabric is sometimes used in industrial applications. For instance, it is used in the film industry to make motion capture suits, which are special types of bodysuits that actors wear in front of green screens. Spandex makes it easier to generate realistic 3D characters by making sure that these suits ride close to the bodies of actors.
Where Is Spandex Fabric Produced?
Spandex fabric is made by many different international corporations. Some of these corporations, such as DuPont , have factories in dozens of different countries, but others may be localized to one country in particular.
The majority of the world's spandex manufacturing plants are located in China. In the past, most of this fabric was produced in the United States, but reduced labor costs have driven the manufacture of many different types of textiles to China over the last few decades.
Plus Prime Flared Cotton Spandex Capri
A recent revival in the U.S. manufacturing economy may preside over a return of spandex production to American shores, but whatever the case may be, market reports project the future of spandex production to be bright . While many types of synthetic textiles have lost popularity in recent years, there is no replacement for spandex, which means that this fabric industry will continue to enjoy increased growth until at least .
How Much Does Spandex Fabric Cost?
Due to its novelty and the relatively laborious manufacturing process used to make it, spandex fabric commands a relatively high market price. It is, for instance, more expensive than polyester and nylon, and it is also usually more expensive than organic fabrics like wool and cotton.
Since elastane is generally only used in small quantities in apparel, however, this increased price does not usually make itself apparent at the consumer level. The more spandex fabric that is included in a garment, however, the more expensive that garment becomes. For instance, certain types of cycling gear and professional dance garments that contain high levels of spandex are quite costly.
What Different Types of Spandex Fabric Are There?
Even when different production methods are used to make spandex, the end result is chemically the same. However, confusion can ensue due to the different terms that are used to describe this fabric:
- Spandex: This term is not a trademark, and it is, in fact, an anagram of "expands." Spandex was never intended to be the primary term used to refer to elastane fabric, but the term stuck in the consumer mind, and most Americans and Canadians now refer to this textile with this term.
- Elastane: Most Europeans use variants of the term "elastane" to refer to this type of fabric. Elastane is the most chemically correct way of referring to this fabric.
- Lycra: This term is a registered trademark of the DuPont Corporation. Only spandex made by DuPont can be called Lycra, but this fabric is chemically identical to fabrics that are called spandex or elastane, and it has the same attributes.
How Does Spandex Fabric Impact the Environment?
Overall, spandex has a negative impact on the environment. This impact is not as pronounced as the negative impact of other types of synthetic fabrics, but it is certainly present, and at this point, no feasible solutions have been suggested to curb the environmental degradation caused by spandex fabric.
If only the production methods used to make spandex are considered, then this fabric does not appear to have a significantly detrimental effect on the environment. Certain synthetic materials, such as nylon, are directly derived from non-renewable resources like coal and petroleum oil, but elastane is made entirely from chemicals that are synthesized in lab settings.
Marine Matte Tricot Spandex Fabric
The production of elastane is, therefore, highly energy-intensive, but if renewable energy sources are used to produce the prepolymers that this fabric consists of, this problem can be solved. There's a possibility that the same health issues that workers encounter in the production of polyurethane are encountered in the production of spandex, but no research has been done into this subject. Additionally, it's possible that isocyanates , which are toxic chemicals commonly found in polyurethane, may also be present in spandex, but there is no clear indication that this is the case.
The notable environmental impact of elastane comes into play only after it is sold to consumers. It has been determined that 60 percent the trash in U.S. waterways is composed of non-biodegradable textile fibers , and spandex garments and fibers make up a large portion of this waste. Even if spandex is disposed of properly in landfills or other designated trash disposal areas, tiny fibers of this substance are introduced into the waterways whenever elastane garments are washed, which harms aquatic life, reduces drinking water quality, and ultimately contributes to the giant trash islands that are steadily accumulating in the world's oceans.
Elastane and other non-biodegradable textiles will be around long after human civilization has departed the planet, and at this time, there are no known methods for converting spandex fabrics and similar materials into biodegradable substances. Safe disposal and limited washings are the only ways to mitigate the environmental impact of this fabric.
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