Polyester Fabric | History of A Synthetic Invention and Use Cases
- Nil Tekstil
- Sep 16
- 6 min read
We frequently come across polyester fabric in our daily lives, thanks to its wide range of applications. But polyester textiles weren't always this common.
Since the early 20th century, industrialization and evolving consumption have rapidly increased fabric demand, a need that limited natural resources wasn't able to fulfill.
This was the turning point for the textile industry's transformation. Efforts to produce synthetic fibers that were easier to produce and longer-lasting than natural fibers were gaining momentum. Polyester—and eventually—polyester fabric was produced.
Discover the story of polyester, its invention and uses across different sectors.
What is Polyester? | the Origin
Towards the end of the 19th century, scientists had their first attempts to produce synthetic fibers. Initially they were able to produce cellulose-based viscose and acetate. Fully synthetic fibers, however, were not yet available.
In 1926, American scientist Wallace Carothers and his team produced the polyamide we know as nylon. This invention was a groundbreaking for many industries, especially textiles.
Wallace Carothers was the first to invent polyester polymers, using alcohol and carboxylic acids. However, his synthetic fibers were not stable enough and would deteriorate when exposed to hot water.
In 1935 American company DuPont was the first to spin the first entirely synthetic fiber of polyamide. In 1938, the first polyamide yarns were introduced to the market.
A year later, synthetic socks were introduced. After a competition in which more than four hundred name suggestions were submitted, the name nylon became the name used for polyamide fibers.
With the outbreak of World War II, the chemical industry in the United States started evolving to support the war effort. The gap was fulfilled by British companies, which continued to invest in synthetic fiber production.
In 1939, two British chemists, John Winfield and James Dickson synthesized polyethylene terephthalate (PET), to produce the raw material for polyester fabric and PET bottles.
The word polyester is a combination of the words "poly," meaning multiple, and "ester," a chemical compound derived from petroleum.
Polyester is a type of polymer, the synthesis of terephthalate and polyethylene. A polymer is a long-chain chemical structure formed by the combination of multiple repeating molecular units (monomers).
Polyester, derived from petroleum-based raw materials, has a versatile and durable structure.
What is Polyester Fabric and Why is It So Common
Polyester fabric is made by spinning and weaving synthetic fibers made from polyester polymers.
When it was first introduced, adapting to polyester fabric wasn't easy.
Polyester fabric has to undergo numerous new processes before it can be ready for use. When it was introduced, many procedures remained new to the technologically backward textile industry.
Despite the many advantages it offered, it took a long time for both manufacturers and consumers to adapt to synthetic fabrics.
By the 1950s however, polyester was becoming known as the "miracle fabric." Around the time, polyester was primarily used in men's suits and was still an expensive material. One of the main reasons for its popularity was its ease of care.
Garments made from polyester fabric are very easy to wash and dry. They also require little ironing. The ease of use helped increased polyester textiles' popularity.
Another reason is the exceptional durability of polyester fabrics. Especially in workers' uniforms, the fabric appears to retain its shape even after long working hours. Its resistance to abrasion, shrinkage, and stretching further confirms its "miracle fabric" appeal.
The miracle fabric polyester also:
Dries quickly. Because of its low moisture absorption, textiles made from this fabric dry quickly. The shortened drying time in industrial laundries means substantial energy savings.
Is fade resistant. As the yarn is deeply dyed, its colors are resistant to washing and fading. The colors remain vibrant and bright for a long time.
Is lightweight and thin. Polyester fabric threads are quite light, and flowy fabrics can also be produced from these threads.
Is suitable for micro-channel technical knitting. It's a good fit for moisture-wicking sports fabrics.
Is resistant to pests and mold. It has a rot-proof and indestructible structure.
Is suitable for blending with other materials. It can be blended with fabrics such as cotton or viscose to enhance comfort depending on the area of use.
Is easy to iron, especially useful for tablecloth fabrics.
Provides ease of washing as it is highly resistant to damages by stain remover chemicals.
In the 1960s, competition in polyester production increased, leading to more competitive prices. This made polyester fabric more accessible to the masses. During the period, synthetic fabrics dominated fashion. The fashion industry launched a wardrobe revolution with brightly colored, smooth, basic, thin, and unusually shaped pieces that showcased synthetic fabrics.
However, this "boom" for polyester reversed in the 1970s. As the market got crowded, polyester textiles were produced in larger quantities, and inferior fabrics were being pushed onto the market.
The perception of polyester as a "miracle fabric" quickly shifted to "cheap and inferior". The rise of the hippie lifestyle during this period, along with the "back to nature" motto, gradually brought natural fibers back into popularity.
Today, polyester fabric dominates the textile industry. It's widely used in hotel and restaurant textiles, corporate wear and uniforms. It continues to be the most produced fiber globally, accounting for 57% of production in 2023.
Recycled Polyester Fabric
It's possible to produce polyester fabrics from recycled polyester, known as rPET. In this method, used PET bottles, clothing, and industrial waste recycles into polyester fiber.
Plastic waste is collected, sorted, cleaned, shredded, and pelletized. The polyester fibers produced from the pellets are extruded into yarn and can be used in fabric production.
Polyester fibers are also suitable for blending with other fibers. The majority of textiles we use in our daily lives are made with polyester blended fabrics. So, what are the uses of polyester fabric?
Uses of Polyester Fabric Across Sectors
Polyester and polyester-blend fabrics have various advantageous qualities, making them widely used across a range of applications.
Pure Polyester Fabrics | Areas of Use
Various garments are made from pure polyester, due to its different qualities:
It's used in sportswear because it's flexible and it dries quickly.
It's used in outerwear such as raincoats and jackets because of its water-repellent properties.
It's also used in work clothes and uniforms because of its durability and wrinkle-resistant structure.
In home textiles, pure polyester is used in curtains, duvet covers and cushion-pillow fillings thanks to its low cost and easy maintenance.
In industrial textiles, it is used to make safety belts, filter fabrics, parachutes, ropes, tent fabrics, packaging, sack fabrics and ropes.
Tablecloth fabrics produced using staple fiber spinning are frequently preferred in hotel and restaurant textiles. These polyester fabrics have a cotton-like appearance, a soft touch, and a matte finish. They dry quickly and are easy to iron, making them a cost-effective fabric.
Polyester Blend Fabrics | Areas of Use
Polycotton
Because polyester yarn blended with cotton significantly increases breathability, polyester-cotton blends—in other words, polycotton—are widely used in the apparel industry. They are preferred in many products, including shirts, school and work uniforms, and bedding sets.
Polyester - Elastan
These blends offer flexibility and durability, making them perfect for sportswear, swimsuits, tights and underwear.
Polyester - Viscose
The flowing appearance of viscose, combined with the vibrant colors and durability of polyester fabric, makes polyester-viscose blends a popular choice for visually striking pieces. Widely used in blouses, tunics, dresses, shawls, and scarves.
Niltekstil's polyester-viscose blend plaid fabrics are highly popular and highly acclaimed for their wool-like appearance.
Polyester - Silk
While silk improves the texture of the fabric, polyester ensures lower production costs. Polyester-silk blends are a great fit for garments such as evening dresses, shawls and scarves,
Polyester - Wool
When wool—a warm yarn—is mixed with polyester, it becomes the perfect blend for winter outerwear products. Polyester-wool blends are commonly used to make suits, coats, overcoats and jackets.
In Conclusion
Since they were first produced, polyester yarns and fabrics have been the subject of controversy. Despite the debates, polyester fabric has now surpassed cotton and become the most widely used fabric in the world.
With technological advancements, efforts are underway to mitigate the disadvantages of polyester fabrics. Recycling PET bottles into yarn is a suggested solution to environmental concerns.
Polyester fabric is often more durable than fabrics made from natural fibers. Because polyester textiles are durable, they wear out more slowly and can be used for longer periods of time. In cases where durability is the key, polyester fabrics turn out to be a more environmentally friendly solution than alternatives.
As Nil Tekstil, we produce our polyester fabrics and textile products in a way that minimizes environmental impact and offer them to our customers at competitive prices.
References
Textile Exchange, Materials Market Report 2024
Smelik, Anneke. (2023). Polyester: A Cultural History. Fashion Practice. 15. 1-21. 10.1080/17569370.2023.2196158.
Meikle, Jeffrey L. 1995. American Plastic: A Cultural History. New
Brunswick NJ: Rutgers University Press.
MSK, The Short History of Polyester Fabric, https://so-sew-easy.com/the-history-of-polyester/?utm_source=chatgpt.com
McClements D, 2022, Polyester: History, Definition, Advantages, and Disadvantages, https://www.xometry.com/resources/materials/polyester/?utm_source=chatgpt.com
Kaya S. Tekstil Dünyasında Polyester Kumaşın Yükselişi, 15.03.2025, Aydın Adnan Menderes Üniversitesi İletişim Fakültesi / Gazetecilik Bölümü Öğrenci Uygulama Haber Sitesi
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