100% Polyester Fabric: Comprehensive Guide

I. What Is 100% Polyester Fabric?

100% Polyester fabric is a synthetic fiber textile made entirely from polyethylene terephthalate (PET). It is one of the most widely used synthetic fibers in the apparel industry due to its durability, wrinkle resistance, colorfastness, and easy care.

Key Characteristics:

• High strength and abrasion resistance

• Lightweight yet resilient

• Wrinkle-resistant, shape-retentive, and quick-drying

• Compatible with functional finishes: water-repellent, stain-resistant, flame-retardant

Applications: 100% polyester fabrics are used in woven and knitted structures, suitable for casual wear, sportswear, uniforms, and outerwear.

II. Applications and Suitable Processes by Thickness

1.Thin / Lightweight Polyester Fabric (20–80 gsm)

Applications:

• T-shirts, lightweight shirts, summer dresses, activewear tops

• Packable raincoats, windbreakers

Suitable Processes:

• Fine woven or tight knitted structures

• Easy dyeing or printing: disperse dyeing, sublimation printing

• Heat-setting to improve shape retention

• Lightweight coating for water-repellent finish

Advantages:

• Lightweight and comfortable for daily wear

• Quick-drying and easy to care for

• Suitable for high-volume production
  

Limitations:

• Low thermal insulation

• Limited wind protection

• Prone to static in dry conditions
  

2.Medium / Midweight Polyester Fabric (90–200 gsm)

Applications:

• Casual jackets, work shirts, trousers, mid-season dresses

• Light outerwear and office uniforms

Suitable Processes:

• Woven or knitted medium-density fabric

• Heat-set to prevent shrinkage

• Functional finishes such as anti-wrinkle, stain-resistant, or water-repellent

• Compatible with embroidery and screen printing

Advantages:

• Balanced durability and comfort

• Holds shape well and resists wrinkling

• Versatile for different garment types

Limitations:

• Slightly heavier than thin fabrics

• Moderate breathability, may require lining for comfort

3.Thick / Heavyweight Polyester Fabric (200–400 gsm)

Applications:

• Winter jackets, coats, parkas, ski jackets, insulated workwear

• Upholstery or heavy-duty uniforms

Suitable Processes:

• High-density weaving or double-layer knitting

• Can be laminated or coated with PU/TPU for waterproof or windproof properties

• Heat-setting for stability and anti-wrinkle

• Suitable for padding with down, cotton, or synthetic insulation

Advantages:

• Excellent durability and abrasion resistance

• Water- and wind-resistant after finishing

• Maintains shape and structure even under heavy wear
  

Limitations:

• Heavier and less breathable

• Higher cost compared to lightweight polyester fabrics

• Not suitable for summer or lightweight garments

III. Key Advantages of 100% Polyester Fabric

1. Durable and abrasion-resistant – suitable for daily wear, sportswear, and outerwear

2. Wrinkle-free and easy to maintain – ideal for uniforms and mass production garments

3. Good dyeing and printing performance – compatible with sublimation, disperse dyeing, and functional coatings

4. Functional finish adaptability – water-repellent, anti-stain, flame-retardant

5. Cost-effective and scalable – ideal for large-scale apparel manufacturing

IV. Main Limitations of 100% Polyester Fabric

1. Low moisture absorption – can feel sticky in hot and humid conditions

2. Static-prone – especially in dry climates or during friction

3. Limited thermal comfort in thin fabrics – requires layering for warmth

4. Heavier in thick versions – not suitable for lightweight garments

5. Environmental impact – synthetic fiber; recycling is needed for sustainability
   

V. Conclusion

100% polyester fabric is one of the most versatile fabrics in the apparel industry.

By selecting the appropriate thickness and applying proper functional finishes, polyester fabrics can meet the needs of lightweight summer wear, midweight office garments, and heavy winter outerwear.

For apparel brands, choosing the right 100% polyester fabric ensures durability, cost-efficiency, functional performance, and scalability, while supporting consistent quality for domestic and