What is polyester fabric ?

Polyester is a synthetic fabric that’s usually derived from petroleum. This fabric is one of the world’s most popular textiles, and it is used in thousands of different consumer and industrial applications.

Chemically, polyester is a polymer primarily composed of compounds within the ester functional group. Most synthetic and some plant-based polyester fibers are made from ethylene, which is a constituent of petroleum that can also be derived from other sources. While some forms of polyester are biodegradable, most of them are not, and polyester production and use contribute to pollution around the world.

Polyester fabric is highly resistant to environmental conditions, which makes it ideal for long-term use in outdoor applications.

Polyester fiber was originally developed for mass consumption by the DuPont Corporation, which also developed other popular synthetic fibers like nylon. During World War II, the Allied powers found themselves in increased need of fibers for parachutes and other war materiel, and after the war, DuPont and other American corporations found a new consumer market for their synthetic materials in the context of the postwar economic boom.

Initially, consumers were enthusiastic about the improved durability profile of polyester compared to natural fibers, and these benefits are still valid today. In recent decades, however, the harmful environmental impact of this synthetic fiber has come to light in great detail, and the consumer stance on polyester has changed significantly.

Nonetheless, polyester remains one of the most widely-produced fabrics in the world, and it’s hard to find consumer apparel that doesn’t contain at least some percentage of polyester fiber. Apparel that contains polyester, however, will melt in extreme heat, while most natural fibers char. Molten fibers can cause irreversible bodily damage.

The production processes used to make polyester may vary depending on the type of polyester is made:

Ethylene Polyester

Ethylene polyester (PET) is the most commonly-produced form of polyester fiber. The primary component of PET is petroleum-derived ethylene, and in the process of creating polyester fiber, ethylene serves as the polymer that interacts with other chemicals to create a stable fibrous compound.

There are four ways to make PET fiber, and the polyester production process varies slightly depending on which method is used:

1.Filament: Polyester filaments are continuous fibers, and these fibers produce smooth and soft fabrics.

2.Staple: Polyester staples resemble the staples used to make cotton yarn, and like cotton staples, polyester staples are usually spun into a yarn-like material.

3.Tow: Polyester tow is like polyester filament, but in polyester tow, the filaments are loosely arranged together.

4.Fiberfill: Fiberfill consists of continuous polyester filaments, but these filaments are produced specifically to have the most possible volume to make bulky products like pillows, outerwear, and stuffing for stuffed animals.

The process of creating polyester fiber begins with reacting ethylene glycol with dimethyl terephthalate at high heat. This reaction results in a monomer, which is then reacted with dimethyl terephthalate again to create a polymer.

This molten polyester polymer is extruded from the reaction chamber in long strips, and these strips are allowed to cool and dry, and then they are broken apart in to small pieces. The resulting chips are then melted again to create a honey-like substance, which is extruded through a spinneret to create fibers.

Depending on whether filaments, staple, tow, or fiberfill fibers are desired, the resulting polyester filaments may be cut or reacted with various chemicals to achieve the correct end result. In most applications, polyester fibers are spun into yarn before they are dyed or subjected to other post-production processes.

PCDT Polyester

The process of creating PCDT polyester is similar to the process of creating PET polyester, but this polyester variant has a different chemical structure. While PCDT also consists of ethylene glycol reacted with dimethyl terephthalate, different production processes are used to make these two common polyester variations.

How is polyester fabric used ? 

It’s important to recognize that the PET used to make polyester fabric is the same type of petroleum-based plastic used to make many of the synthetic consumer products we use in our daily lives. For instance, this plastic is used to make food containers, water bottles, and a variety of other types of industrial and consumer products.

In its fiber form as polyester fabric, however, PET is used in hundreds of different consumer applications. Traditionally, PET has been used as an alternative to cotton, and in some applications, it may also serve as a reasonable alternative to other natural fibers like wool and silk.

Essentially, anything made from cotton can also be made with polyester. From everyday shirts and pants to glamorous eveningwear, the apparel applications of polyester fabric are endless. Manufacturers use polyester fabric to make suits, jackets, socks, underwear, and pretty much anything that you can wear for casual, business, or formal occasions.

Carlo Black Luxe Polyester Fabric

Additionally, manufacturers also use polyester to craft various homewares. In particular, a type of polyester called microfiber has gained prominence in the bath and kitchen homeware categories. Consumers value the softness and absorbency of microfiber in applications like bath towels, face towels, and kitchen towels. Manufacturers may also use polyester to make homewares like blankets, rugs, upholstery, and curtains.

Polyester fabric may be used as cushioning for chairs, sofas, and pillows, and due to the impressive stain-resistance of this material, many parents and pet owners prefer polyester products. Industrial applications of polyester include LCD displays, holographic film, boats, tarps, and bottles.

Where is polyester fabric produced ? 

According to a 2006 study, China is the largetst producer of polyester fabrics. China is also the world’s largest polyester market, which makes this nation the hub of the international polyester industry.

Taiwan, Korea, India, Japan, and Indonesia are also major manufacturers of polyester, and some polyester production still occurs in the United States. Once polyester fibers are produced in China and other Asian countries, they mainly remain in Asia to be made into apparel and other polyester-based consumables. From there, these finished pieces of polyester apparel are exported to various nations in the Western world and beyond.