Behind the base layer scene: How polyester spandex fabric is made

Behind the base layer scene: How polyester spandex fabric is made

What is Polyester Spandex Fabric?

Polyester spandex fabric, is a versatile textile that combines the properties of both polyester and spandex fibers. It is widely used in the fashion industry for its stretchability, durability, and comfort.

How is Polyester Spandex Fabric Made?

The production process of polyester spandex fabric involves the combination of polyester and spandex fibers. Here is a step-by-step guide on how this fabric is made:

Step 1: Polyester Production

The first step in making polyester spandex fabric is the production of polyester fibers. Polyester is a synthetic fiber. It is made through a process called polymerization, where petrochemicals are reacted to form long chains of polyester molecules. These chains are then spun into fibers.

Step 2: Spandex Production

Simultaneously, spandex fibers are produced using a different process. Spandex, also known as elastane, is a synthetic fiber known for its exceptional stretch and recovery properties. It is made from a polymer called polyurethane, which is spun into fibers.

Step 3: Blending Polyester and Spandex

Once the polyester and spandex fibers are produced, they are blended together in a specific ratio. The ratio of polyester to spandex can vary depending on the desired stretch and properties of the final fabric. The fibers are mixed together to create a homogeneous blend.

Step 4: Knitting or Weaving

After the blending process, the polyester spandex blend is either knitted or woven into fabric. Knitting involves interlocking loops of yarn, while weaving involves the interlacing of horizontal and vertical yarns. Both methods create a fabric structure that provides stretch and flexibility. Most of Hot Chillys base layers are knitted.

Step 5: Finishing

Once the fabric is knitted or woven, it undergoes various finishing processes. These processes include washing, brushing, dyeing, and applying special treatments such as anti-odor or moisture-wicking finishes. The finishing processes enhance the fabric's appearance, performance, and durability.


Polyester spandex fabric is a unique textile that combines the properties of polyester and spandex fibers. It is made through a process that involves the production of polyester and spandex fibers, blending them together, and knitting or weaving them into fabric. The resulting fabric is stretchable, durable, and comfortable, making it ideal for a wide range of applications in the outdoor industry.


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