Blog / Beginner's handbook / What is Polyester? Uses, Benefits & Drawbacks
Blog / Beginner's handbook / What is Polyester? Uses, Benefits & Drawbacks
Polyester is the most widely used fabric in the world. From activewear to home textiles, it has become a staple in countless industries. But what is polyester, and why is it so popular?
In this comprehensive guide, we’ll explore the origins, properties, and uses of polyester fabric. We’ll also dive into its advantages, drawbacks, and the environmental impact of its production.
Whether you’re curious about how polyester is made, the types available, or how it stacks up against other fabrics, this article will give you everything you need to know. Let’s explore!
Polyester fabric is a synthetic textile made from petroleum-based polymers. First introduced in 1941, it quickly became popular for being durable, versatile, and cheap. Now, polyester is the most widely used fiber in the world. It accounts for more than half of the overall fiber market.
Polyester fibers are strong, wrinkle-resistant, and quick to dry, which makes it a popular fabric choice for everything from casual wear to custom embroidery projects.
Unlike natural fibers like cotton or wool, polyester is entirely man-made. Its synthetic nature allows manufacturers to engineer specific properties. For example, fibers can be made to be moisture-wicking, UV-resistant, or even flame-retardant.
Polyester fabric is used across various industries due to its adaptability and performance. In clothing, it’s a popular choice for activewear, outerwear, and everyday garments. Polyester is often blended with natural fibers like cotton to provide greater comfort.
In home textiles, polyester is great for items like curtains, upholstery, bed linens, and carpets, thanks to its strength and stain resistance. Its ability to withstand wear and resistance to abrasion also makes it a valuable material in industrial applications producing ropes, conveyor belts, and safety harnesses.
The fabric’s smooth surface makes it particularly suitable for products in the print-on-demand industry, where it’s common to print custom t-shirts and apparel. Sublimation printing on polyester ensures vibrant, long-lasting designs, making it a favorite for personalized items.
Source: Printful
Polyester exists in several forms, each designed for specific applications. The most common type in the textile industry is PET (Polyethylene Terephthalate). It’s primarily used in clothing, home textiles, and packaging due to its lightweight, durable, and easily dyeable properties. PET is a popular choice for trending products like vibrant, custom-printed apparel.
Another variant, PCDT (Poly-1, 4-Cyclohexylene-Dimethylene Terephthalate), is less common but more elastic than PET, making it suitable for heavy-duty uses like upholstery and curtains. Elasticity contributes to durability and resilience in textiles, so even when subjected to frequent use, pulling, or stretching, the fabric retains its shape and functionality.
Microfiber polyester, crafted from ultra-fine polyester fibers, stands out for its softness and lightweight feel. For this reason it’s a popular choice for athletic wear and cleaning materials.
In recent years, recycled polyester, made from plastic bottles, has appeared as a more sustainable alternative. It’s now used in apparel like crop tops and bikinis, combining eco-friendly materials with modern design.
Source: Pexels
Polyester is made through a chemical process called polymerization, which combines petroleum-derived compounds like ethylene glycol and terephthalic acid. These compounds are heated and fused to form long chains of polymers, which are then cooled and cut into small chips.
The chips are melted and pushed through the small holes of spinnerets to create polyester fibers. They are stretched and processed to achieve the desired strength and elasticity. These fibers can then be woven or knitted into fabric.
While traditional polyester fabric relies on petroleum, advancements in technology have enabled the production of recycled polyester, which uses materials like plastic bottles or discarded textiles.
Despite its benefits, polyester production has major environmental drawbacks. The biggest issues are the reliance on fossil fuels, energy consumption, and its contribution to microplastic pollution.
Polyester is a go-to fabric for many industries. It’s resistant to shrinking, stretching, and wrinkles, making it a practical option for clothing, bags, and home textiles.
One of polyester’s standout features is its moisture-wicking ability, which means it keeps you dry and comfortable during workouts or hot days. Unlike cotton, which absorbs sweat, polyester pushes moisture to the surface of the fabric, where it evaporates quickly.
Adidas running jacket made from recycled polyester. Source: Adidas
If you’ve ever worn a polyester t-shirt or jacket and noticed how it stayed dry even during intense activities, that’s the moisture-wicking magic at work. While it’s great for staying dry, polyester’s breathability can sometimes be a downside in very hot conditions, so it’s often paired with mesh panels or other cooling features for added comfort.
Polyester is great at holding onto heat, which makes it a popular choice for cold-weather clothing like jackets, thermal layers, and fleece blankets. Its tightly woven fibers trap body heat, helping you stay warm when temperatures drop. This is especially handy for outdoor gear designed for winter sports or chilly climates.
However, this can also make polyester fabric less comfortable in hot weather, as it doesn’t release heat as easily as natural fibers. To balance this out, many garments use polyester blends to improve airflow.
Polyester isn’t naturally stretchy, but when combined with elastic fibers like spandex, it becomes a powerhouse for activewear and fitted clothing. You’ll find stretchy polyester blends in everything from leggings to athletic gear because they allow for freedom of movement while maintaining their shape. Even on its own, polyester has a slight give, which helps it stay durable.
Let’s explore the key advantages that make polyester a versatile and practical fabric.
Source: Pexels
Polyester is known for its ability to withstand shrinking, general wear and tear, and loss of shape. Unlike natural fibers that can degrade over time, polyester maintains its flexibility and integrity even after repeated use and washing.
This makes it an excellent choice for clothing, upholstery, bags, and outdoor gear designed for frequent use. Polyester products remain functional and visually appealing for a long time, providing great value for both manufacturers and consumers.
All-over print duffle bag. Source: Printful
One of polyester’s standout features is its lightweight, compact nature. It also resists wrinkling, so there’s no need for frequent ironing. This makes polyester a favorite for travel-friendly clothing and garments that need to maintain a polished look throughout the day.
Whether used in formal wear, casual outfits, or home textiles, polyester helps maintain a neat and professional look with minimal effort, making it a practical choice for busy lifestyles.
Polyester’s synthetic fibers naturally repel water, allowing the fabric to dry much faster than cotton or other natural materials. This quick-drying feature is particularly beneficial for activewear and outdoor clothing, where staying dry and comfortable is essential. Polyester also wicks moisture away from the skin, keeping the wearer cool and dry during intense physical activity.
These properties make polyester a go-to material for sportswear, workout gear, and even weather-resistant outdoor apparel.
Source: Printful
Polyester’s ability to retain dye is one of its best features. The fabric absorbs color evenly, resulting in vibrant and consistent hues that don’t fade over time. This makes polyester an ideal choice for garments and products featuring bold, durable prints.
Even after multiple washes, polyester fabric maintains its color intensity, ensuring a longer lifespan for clothing and accessories.
All-over print leggings. Source: Printful
Polyester is often more affordable than cotton or wool, making it a cheaper option for manufacturers and consumers. Its lower production costs, combined with its durability, provide great value for money.
Polyester is widely available and easy to produce in large quantities, which helps keep prices competitive. For consumers, this means access to high-quality products at a fraction of the cost of natural alternatives, making polyester a budget-friendly option for clothing and home textiles.
Although polyester offers many advantages, it’s not without its downsides. Let’s take a look at the common drawbacks of polyester fabric.
Source: Pexels
While polyester has plenty of benefits, one common drawback is its tendency to trap odors. This happens because polyester’s synthetic fibers can hold onto sweat, especially during intense activities. If you’ve ever noticed a workout shirt smelling less than fresh even after washing, you’re not alone—this is a known challenge with polyester fabric.
The good news is that there are solutions! Many modern polyester garments are treated with antimicrobial finishes to combat odor-causing bacteria. Plus, proper care, like washing in cold water with appropriate detergents, can help keep your polyester clothing fresh.
Polyester fabric is prone to static electricity, especially in dry conditions. This static buildup can cause the fabric to cling to the skin or attract dust, lint, and pet hair, which can be frustrating for wearers. While anti-static treatments and fabric softeners can help mitigate this issue, it remains a common complaint.
The production of polyester is heavily dependent on petroleum, a finite and non-renewable resource. This raises significant sustainability concerns in a world increasingly focused on reducing fossil fuel reliance. Polyester fabric also requires high amounts of energy to produce, emitting 14.2 kg of CO2 per each kilogram of fabric produced.
Beyond its resource-intensive manufacturing process, polyester poses environmental threats through microplastic pollution. Recent studies show that with each wash, tiny synthetic fibers are released into wastewater systems, ultimately infiltrating rivers, oceans, and marine ecosystems, where they can harm aquatic life and enter the food chain.
Although recycled polyester provides a more sustainable alternative by repurposing existing plastic waste, it remains a small fraction of global polyester production. Currently, the overall market share of recycled polyester stands at only 12.5%.
Polyester fabric can qualify for various certifications. For example, OEKO-TEX offers its Standard 100 certification for polyester textiles that meet strict safety and environmental standards, ensuring they are free from harmful substances.
Recycled polyester can also earn the Global Recycle Standard (GRS) certification, which verifies the authenticity of recycled materials and promotes sustainable production practices. Intertek also provides certifications for recycled PET fabrics.
It’s important to note that polyester, being a synthetic fabric, cannot qualify for organic certification. Even plant-based polyester undergoes extensive chemical processing. Certifications like GRS or OEKO-TEX can help bridge this gap by assuring consumers of the fabric’s safety and sustainability credentials.
Polyester fabric has revolutionized industries with its durability, lightweight nature, and ability to meet diverse needs—from activewear to vibrant custom apparel. Whether you’re designing products, shopping for clothing, or simply curious about textiles, polyester remains a fascinating fabric in modern life.
However, it’s important to balance its benefits with its environmental impact. As consumers and manufacturers increasingly prioritize sustainability, innovations like recycled polyester are paving the way for a more eco-friendly future.
Recycled polyester, often called rPET, is made by repurposing plastic waste like PET bottles into polyester fibers. This process reduces the need for new polyester production, conserving resources and lowering environmental impact.
Polyester itself is not inherently stretchy, but it does have some flexibility. To enhance stretchiness, it’s often blended with elastic fibers like spandex or elastane. This makes polyester blends ideal for activewear and fitted garments.
Polyester is generally safe to wear and use, but it can cause irritation for people with sensitive skin, especially if worn for long periods in hot conditions. Additionally, concerns about polyester fabric stem from its synthetic materials, which means it’s less breathable than cotton or linen, and can contribute to microplastic pollution during washing.
The choice between polyester and cotton depends on your needs. Polyester is durable and quick-drying, making it great for activewear and outdoor use. Cotton is natural, breathable, and soft, ideal for comfort and everyday wear. Fabric blends often combine the best of both worlds.
Both nylon and polyester are synthetic materials, but they each bring unique strengths to the table. Nylon is known for its strength and durability, so it’s a go-to choice for heavy-duty applications like outdoor gear, luggage, and ropes.
On the other hand, polyester is lightweight, less likely to fade in sunlight and dries quickly, therefore it’s a practical option for outdoor clothing, furnishings, and activewear. Polyester fabric is also more affordable than nylon.
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By Sandra Ķempele on Feb. 4, 2025
Sandra Ķempele
Guest author
Sandra is a freelance writer and educator with a background in art and communication. She holds an MA in Art Museum and Gallery Studies, and in her free time enjoys reading, museum visits, and outdoor adventures.
Sandra is a freelance writer and educator with a background in art and communication. She holds an MA in Art Museum and Gallery Studies, and in her free time enjoys reading, museum visits, and outdoor adventures.
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9 min read Feb. 4, 2025
By Katrina Resne 11 min read
By Karlina Rozkalne 21 min read
By Cloe Ann Montoya 20 min read
By Una Berzina-Pudule 13 min read
By Gabriela Martinez 20 min read
By Karlina Rozkalne 9 min read