Polyester is a synthetic fabric made from petroleum-based chemicals. It is a man-made fabric that is strong, wrinkle-resistant, and quick-drying. It is one of the most commonly used materials in the textile industry and in thousands of different consumer and industrial applications.
This fabric is a synthetic polymer compound that contains the ester functional group. A certain type of eco-friendly polyester is biodegradable.
Polyester is often blended with cotton or other natural fibers to reduce production costs and enhance durability. While 100% polyester is less comfortable, blending it with cotton improves shrink resistance, wrinkle control, and fabric strength. Its resistance to environmental factors also makes it ideal for long-lasting outdoor wear.
How Is Polyester Made?
Polyester is a synthetic fabric made through a complex chemical process that transforms petroleum or plant-based materials into strong, durable fibers. Most commonly, polyester refers to polyethylene terephthalate (PET), the same plastic used in water bottles. While the production process can vary slightly based on the type of polyester such as PET, PCDT, or bio-based versions—the core steps remain largely consistent.
Step-by-Step Process of Polyester Fabric Manufacturing
1. Raw Material Sourcing
The process begins with ethylene, a compound typically derived from petroleum but also obtainable from renewable sources like sugarcane in eco-friendly polyester production. Alongside dimethyl terephthalate (DMT) or terephthalic acid (TPA), these components act as the building blocks for polyester.
2. Polymerization
Ethylene glycol is reacted with dimethyl terephthalate at high heat to create a monomer. This is further processed to form the polymer PET (polyethylene terephthalate). At this stage, the substance resembles a thick, honey-like liquid.
3. Extrusion and Cooling
The molten PET is extruded into long strips, cooled, and then cut into small pellets or chips. These chips serve as the raw material for creating polyester fibers.
4. Fiber Formation (Spinning)
The pellets are reheated and melted again, then pushed through tiny holes in a spinneret—a metal device similar to a showerhead. As the melted polymer passes through, it forms long threads that harden upon cooling into polyester fibers. The shape of the spinneret can be customized to influence the texture, strength, and finish of the fibers.
5. Fiber Types and Applications
Depending on the desired end use, the resulting fibers may be processed into various forms:
- Filament Fibers: Continuous strands ideal for smooth and silky fabrics.
- Staple Fibers: Cut into short lengths, similar to cotton, and spun into yarns.
- Tow: Loosely gathered filaments, often processed into staple fiber.
- Fiberfill: Fluffy, voluminous fibers used in insulation, bedding, and stuffed items.
After this, the fibers are usually twisted into yarn, dyed, and woven or knitted into fabrics for various industries—from apparel and home textiles to industrial and packaging applications.
What Does 100% Polyester Mean?
When a product is labeled as 100% polyester, it means the fabric is made entirely from polyester fibers without being blended with any other material like cotton or rayon. 100% polyester fabric is known for its strength, wrinkle resistance, quick-drying capabilities, and color retention. It’s commonly used in apparel, sportswear, home furnishings, and industrial textiles due to its durability and easy care.
Is Polyester a Good Fabric Choice?
Yes, polyester is a good fabric choice for many applications—especially where durability, low maintenance, and affordability are key. Its resistance to shrinking, fading, and stretching makes it ideal for everything from activewear to uniforms and outdoor gear.
Pros:
- Long-lasting and wear-resistant
- Quick to dry and wrinkle-free
- Colorfast—retains vibrant colors
- Low maintenance and machine washable
Cons:
- Less breathable than cotton
- Derived from petroleum (non-renewable)
- Can hold onto odors if not treated
The Power of Polyester
The true power of polyester lies in its versatility and adaptability. It can be woven to feel soft like silk, durable like canvas, or flexible like spandex. Polyester is also commonly blended with other fibers (like cotton or elastane) to enhance comfort and stretch while maintaining its core strength.
In the fashion industry, polyester is used to create everything from fast fashion to luxury activewear, while in home textiles, it’s favored for curtains, upholstery, and bed linens due to its wrinkle resistance and longevity.
How Polyester Compares to Other Fabrics
Polyester is more durable and water-resistant than cotton, making it ideal for sportswear. While cotton is softer and more breathable, it can shrink and wear out faster. Compared to nylon, polyester is more UV-resistant and dries quicker, though nylon is stronger and stretchier. Against rayon, polyester is less likely to wrinkle and holds color better.
Polyester vs Other Fabrics Overview:
- Cotton: Natural, breathable, but shrinks easily
- Nylon: Stronger and stretchier but less UV-resistant
- Rayon: Softer feel, but wrinkles more
- Spandex: Very stretchy, usually blended with polyester
Types of Polyester
Polyester isn’t just one fabric—it comes in various types tailored to specific uses:
- PET Polyester (Polyethylene Terephthalate)
The most common form; used in clothing, packaging, and plastic bottles.
- PCDT Polyester
Offers greater elasticity and durability; used for heavy-duty textiles.
- Microfiber Polyester
Extremely fine fibers that create a soft, luxurious feel—great for athletic wear, bedsheets, and cleaning cloths.
- Recycled Polyester (rPET)
Made from recycled plastic bottles, offering a more sustainable alternative.
- Plant-Based Polyester
An emerging eco-friendly type made using ethylene from renewable sources like sugarcane instead of petroleum.
Polyester Fabric Cost
The cost of polyester fabric varies depending on quality, weave, and production process. On average, the price of polyester per kilogram ranges from $50 to $100 for general industrial use. Its low cost combined with high performance makes it a preferred fabric in mass manufacturing.
Where to Buy High-Quality Polyester Fabric or Clothing
To ensure the best results when working with polyester fabric, it’s essential to partner with experienced clothing manufacturers like Fabletic Sports. Polyester requires precision cutting and sewing techniques to produce high-quality garments, especially for activewear, uniforms, and custom apparel.
Fabletic Sports clothing manufacturer offer complete production solutions and often work with a range of materials, including spandex, lycra, twill, lyocell, rayon, and nylon. These blends help enhance the final product’s comfort, stretchability, and durability.
Conclusion
Polyester is a durable, water-resistant synthetic fabric widely used in sportswear, workwear, and industrial textiles. While it can trap heat and isn’t biodegradable, its affordability, strength, and easy availability make it a practical choice. For quality results, it’s best to source from reliable like polyester fabric supplier.
Fabletic Sports offering polyester made clothing, like T-shirts, sports uniforms, hoodies and more. Explore our category for more information.
FAQs
1- Where does polyester come from?
Polyester fabric is a man-made material derived from petroleum-based synthetic polymers, also known as polyethylene terephthalate (PET).
2- What is the main difference between polyester and cotton?
Polyester is a synthetic, moisture-resistant, and durable material, while cotton is an organic, biodegradable, and breathable fabric.
3- Is polyester sustainable?
Traditional polyester is not sustainable. However, recycled polyester (rPET) is an eco-friendly alternative.
4- Is 100% polyester fabric breathable?
No, 100% polyester is not highly breathable. It tends to trap heat and moisture, but moisture-wicking finishes can improve comfort.
5- Can polyester fabric be washed at home?
Yes, polyester is machine washable, wrinkle-resistant, and easy to care for. Use cold or warm water and avoid high heat when drying.
6- Is polyester eco-friendly?
Traditional polyester is not biodegradable and is made from petroleum. However, recycled polyester (rPET) offers a more sustainable option.
