Polyester Fabric – Everything You Need To Know

Polyester fabric, a synthetic fabric derived mostly from petroleum, is one of the world’s most popular textiles, used in a vast array of consumer and industrial products. It’s a polymer made primarily of compounds from the ester group, with most synthetic varieties and some plant-based ones produced from ethylene. Despite its wide use, polyester is predominantly non-biodegradable, contributing to global pollution.

Filament Polyester Fabric

Often, polyester is used in apparel either alone or blended with natural fibers like cotton to cut costs and improve certain qualities such as shrink resistance, durability, and wrinkle resistance. However, this blend tends to reduce garment comfort. Polyester’s resistance to environmental factors makes it suitable for long-lasting outdoor use.

The development of polyester began in 1926 in the UK with the synthesis of Terylene by W.H. Carothers. The material gained prominence, especially in the US, through the efforts of the DuPont Corporation, which commercialized it alongside other synthetic fibers like nylon. Its importance grew during World War II due to its use in military supplies, and its popularity soared in the post-war consumer boom due to its durability.

However, the environmental drawbacks of polyester have become more evident, leading to a shift in consumer attitudes. Despite this, polyester’s presence in the apparel industry remains strong, found in many garments. It’s important to note that polyester garments can melt under extreme heat, posing a risk of severe burns, unlike most natural fibers that char.

Different Types of Polyester Fabrics

Polyester Fabric

Polyester is a synthetic fabric derived from petroleum-based products, characterized by its durable and strong nature. At its core, polyester is a polymer, or a long chain of repeating molecular units, which gives it the unique properties that make it so versatile. The fabric is primarily made from polyethylene terephthalate (PET), although there are variations, such as polybutylene terephthalate (PBT) and polycyclohexylenedimethylene terephthalate (PCDT), which offer different characteristics for specific applications.

There are several types of polyester fabrics, each designed to exploit certain properties of the material:

PET Polyester: The most common type used in textiles, PET polyester, is renowned for its strength, durability, and resistance to shrinking and stretching. It’s the go-to material for a vast array of clothing and home furnishing products.

PCDT Polyester: Though similar to PET, PCDT polyester offers a higher degree of elasticity and resilience, making it ideal for heavier applications, such as draperies and upholstery.

Blended Polyester: Polyester is often blended with natural fibers, such as cotton or wool, to combine the best properties of both materials. These blends offer the durability and wrinkle resistance of polyester while maintaining the comfort and breathability of the natural fibers.

How is Polyester Made?

The production of polyester fabric is a complex chemical process that begins with the extraction of crude oil. The oil is refined and transformed into the chemical building blocks of polyester, including ethylene glycol and terephthalic acid. These components undergo a polymerization process, where they are combined under high heat and pressure to form the polymer chips. These chips are then melted and extruded through a spinneret, a device that functions much like a showerhead, to form long, thin fibers. Once cooled, these fibers are spun into yarn, which can be woven or knitted into polyester fabric.

Recent advancements in manufacturing technologies have focused on making the polyester production process more sustainable and environmentally friendly. Innovations include recycling existing polyester products and using renewable resources to create the polyester polymer, significantly reducing the reliance on fossil fuels and lowering the carbon footprint of polyester fabric production.

Properties of Polyester Fabric

Polyester fabric boasts a wide range of properties that make it a preferred choice in various applications:

  • Durability and Strength: Polyester is known for its high tensile strength, making it resistant to stretching, shrinking, and most chemicals.
  • Elasticity and Shrink Resistance: The fabric maintains its shape and resists wrinkles, making it ideal for clothing that requires minimal ironing.
  • Quick-Drying and Water-Resistant Qualities: Polyester fibers are hydrophobic, meaning they repel water, allowing the fabric to dry quickly.
  • Wrinkle and Abrasion Resistance: Polyester garments are durable and maintain their appearance over time, resisting tears and abrasions.

Uses of Polyester Fabric

PET Fabric

Polyester’s remarkable versatility and durability have made it a ubiquitous presence in various sectors, far beyond the realms of fashion and textiles. Its applications range from everyday clothing to high-end technological uses, showcasing the material’s adaptability and functionality.

  • Apparel and Fashion Industry: Polyester is a staple in the apparel industry, valued for its durability, wrinkle resistance, and ease of care. It is widely used in activewear due to its moisture-wicking properties, as well as in outerwear, suits, and dresses for its ability to hold shape and resist environmental elements.
  • Home Furnishings: The strength and aesthetic flexibility of polyester make it a popular choice for home decor items such as curtains, upholstery, carpets, and beddings. Its ability to mimic the appearance of natural fibers, while offering superior durability and stain resistance, makes it ideal for households seeking practicality and style.
  • Industrial Applications: Beyond its use in consumer products, polyester plays a crucial role in various industrial applications. It is used in making conveyor belts, hoses, tarps, and nets due to its strength and resistance to wear and tear. Polyester fibers are also used in the manufacturing of ropes and cords, benefiting from the material’s high tensile strength and elasticity.
  • Innovative Uses in Technology and Sustainability Efforts: Polyester’s role in innovation is notable, with applications in areas such as filtration, insulation, and even in the medical field for surgical sutures and implants. Additionally, the material is at the forefront of sustainability efforts, with recycled polyester being used to create new garments and products, thereby reducing waste and dependence on virgin resources.

Advantages of Polyester

Polyester fabric offers a multitude of advantages that contribute to its popularity and widespread use:

  • Cost-Effectiveness: Compared to natural fibers, polyester is generally more affordable to produce, making products more accessible to a wider audience.
  • Versatility: The ability to be engineered in various forms, blends, and finishes allows polyester to meet a wide range of performance and aesthetic requirements.
  • Easy Care and Maintenance: Polyester garments are easy to care for, requiring minimal ironing and capable of withstanding frequent washing without losing their shape or color.

Challenges and Criticisms of Polyester

Despite its benefits, polyester faces criticism, primarily related to environmental concerns:

  • Environmental Impact: The production of polyester is energy-intensive and relies on non-renewable resources, contributing to pollution and the depletion of fossil fuels.
  • Sustainability and Recycling Issues: While efforts are being made to recycle polyester, challenges remain in the process’s efficiency and the quality of the recycled material.
  • Microplastic Pollution: Washing polyester fabrics can release microplastics into waterways, posing a threat to aquatic life and ecosystems.

Polyester and Sustainability

Re-polyester Fabric Process

Addressing the environmental challenges of polyester production and use is critical. Efforts to improve the sustainability of polyester include:

  • Recycling Polyester Fabric: Initiatives to recycle post-consumer and post-industrial polyester are growing, aiming to reduce waste and create a circular economy for textiles.
  • Developing Bio-Based Polyester Alternatives: Research into bio-based alternatives to traditional polyester aims to reduce the dependency on fossil fuels and lower the carbon footprint of fabric production.
  • Promoting Sustainable Practices: The fashion industry is increasingly embracing sustainable practices, including the use of recycled polyester, to mitigate environmental impacts.

These efforts represent steps towards a more sustainable future for polyester fabric, balancing its practical benefits with environmental responsibility.


In the vast and ever-evolving textile industry, polyester fabric stands out as a cornerstone of innovation and versatility. Renowned for its durability, ease of care, and wide range of applications, polyester has cemented its place not only in our wardrobes but also in various aspects of our daily lives. From the sleek outerwear that shields us against the elements to the soft linens that adorn our homes, polyester’s presence is ubiquitous, weaving its way into countless products and industries. Welcome get more knowledge about fabrics in Valtin Apparel!


To further your understanding of polyester fabric, here are answers to some frequently asked questions:

Q: Can polyester be recycled? A: Yes, polyester can be recycled, and doing so plays a crucial role in reducing its environmental impact. Recycled polyester is made from existing polyester products and can be used to create new garments and textiles.

Q: Is polyester breathable? A: Polyester’s breathability largely depends on the fabric’s weave and finish. While traditionally less breathable than natural fibers, technological advancements have led to the development of more breathable polyester fabrics, especially for athletic and active wear.

Q: How does washing polyester impact the environment? A: Washing polyester can release microplastics into waterways, contributing to pollution. Using a microfiber catching laundry bag or filter can help reduce this impact.

Q: Are there sustainable alternatives to traditional polyester? A: Yes, sustainable alternatives include recycled polyester and bio-based polyesters, which aim to reduce reliance on fossil fuels and lower environmental footprints.

By providing comprehensive insights into polyester fabric, this article aims to enhance appreciation for this versatile material while promoting a more informed and sustainable approach to its use and care.

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Raymond Lau

Hey, I’m Raymond Lau, the senior account manager of Valtin Apparel.
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