Polyester and Nylon are often at the centre of discussions due to their widespread use and versatile applications within sportswear
Both materials have established a significant presence in industries such as Activewear, sportswear, outdoor gear, and fast fashion.
However, while polyester and nylon share similarities, they also differ in ways that can influence their performance, cost, sustainability, and overall feel. In this blog, we’ll delve into the key differences and similarities between these two popular fabrics, exploring their origins, properties, uses, and environmental impact.

1. Origins and Composition
Polyester:
Polyester, short for “polyethylene terephthalate” (PET), was first developed in the early 20th century and became widely commercialised in the 1950s. The fibre is derived from petroleum-based chemicals and is synthesised through a process called polymerisation, where chemical compounds are bonded to create a long chain of molecules. Polyester became popular due to its durability, resistance to shrinking, and ability to hold its shape over time. The fibre is also cheap to produce and therefore offered a more cost-effective solution to other natural performance fibres such as wool and cotton.
Nylon:
Nylon was the first synthetic fibre to be developed, with its invention dating back to the 1930s by Wallace Carothers at DuPont. Initially, it was designed to replace silk in stockings and parachutes. Just like polyester, nylon is made from petrochemicals. The production process involves a polymerisation reaction, which forms a substance called nylon salt that is later extruded into fibres. Nylon is also a polymer, though its chemical structure varies from polyester, leading to different properties.
2. Texture and Feel
One of the most significant differences between polyester and nylon is how they feel when worn or touched.
- Polyester tends to have a slightly coarser texture, especially in its unmodified form. While advances in manufacturing processes have enabled the production of softer polyester fabrics, they often still lack the silky smoothness of nylon. Polyester has a slightly stiffer feel, making it excellent for garments that require more structure and durability.
- Nylon is known for its soft, smooth, and silky texture. It feels more luxurious and is often used in garments that need a softer feel against the skin, such as lingerie, hosiery, and activewear. Nylon’s slick surface makes it ideal for items like windbreakers and performance gear because it helps reduce friction and improve comfort during movement.
3. Durability and Strength
Both polyester and nylon are durable fibres, but nylon tends to have the edge in terms of strength.
- Nylon is exceptionally strong, highly elastic, and abrasion-resistant, making it perfect for high-stress applications like outdoor gear (backpacks, tents) and sports equipment. It is also more resistant to wear and tear, which is why it’s often chosen for products that undergo a lot of physical stress, like ropes and parachutes. Outdoor, ski and sailing jackets are predominantly produced using Nylon as the fibre offers greater abrasion and tear strength.
- Polyester is also durable but is less strong than nylon in terms of tensile strength. However, polyester’s durability lies in its resistance to stretching, shrinking, and wrinkling, which makes it ideal for everyday clothing like Activewear T-shirts and sportswear outerwear. While polyester may not be as tough as nylon in heavy-duty applications, it holds up well in many active sportswear products.
4. Moisture-Wicking and Water Resistance
Another significant difference between polyester and nylon lies in their moisture management capabilities.
- Polyester is hydrophobic, meaning it repels water. This property makes polyester excellent at wicking moisture away from the skin, allowing it to evaporate quickly, which is why it’s a common choice for sportswear and activewear. Polyester’s ability to wick moisture helps keep the wearer dry and comfortable during intense physical activities.
- Nylon, on the other hand, absorbs more water than polyester, although it is still relatively quick drying compared to natural fibres like cotton. However, because nylon absorbs more moisture, it can feel clammy and uncomfortable in humid or wet conditions. This is a disadvantage for performance gear but less problematic in other applications.
5. Breathability
When it comes to breathability, neither polyester nor nylon can compare to natural fibres like cotton or wool, but there are some differences worth noting.
- Polyester is generally more breathable than nylon, as it is less dense and can be woven into lightweight, airy fabrics. This makes polyester a better option for garments designed for hot weather or intense physical activity over nylon, as it allows for more airflow and better moisture management. Note however, synthetic fibres generally make you hot and therefore sweat more than wearing a natural fibre such as cotton or superfine merino.
- Nylon is less breathable than polyester and tends to trap more heat and moisture, which can make it feel uncomfortable during strenuous exercise or in hot climates. However, advances in fabric technologies, such as the use of mesh panels or special weaves, have improved the breathability of nylon in certain applications.
6. UV and Heat Resistance
Both polyester and nylon are sensitive to ultraviolet (UV) light, but polyester has better UV resistance.
- Polyester is more resistant to fading and degradation from sunlight exposure, making it a superior choice for outdoor applications such as tents, awnings, and outdoor furniture. Polyester can withstand higher temperatures without deforming or melting, which is another reason it’s favoured for outdoor use.
- Nylon, while still durable, is more prone to UV damage and can degrade more quickly when exposed to direct sunlight for prolonged periods. It also has a lower melting point than polyester, meaning it may not hold up as well in high-heat environments.
7. Cost
Cost is a significant factor when deciding between polyester and nylon, especially for manufacturers and consumers looking for budget-friendly options.
- Polyester is generally less expensive to produce than nylon. This is due to the relative simplicity of the production process and the availability of raw materials. As a result, polyester is often the go-to choice for affordable activewear clothing, home furnishings, and textiles.
- Nylon, being more expensive to produce, is typically found in higher-end products or items that require superior durability and strength, such as outdoor apparel, ropes, and technical sportswear fabrics. Nylon’s higher price point reflects its superior performance in certain conditions, but for everyday applications, polyester’s affordability makes it a popular choice. This is why you see so many fast fashion, budget fashion brands using polyester across their entire range.
8. Environmental Impact
Both polyester and nylon are derived from petroleum, making them non-renewable and contributing to their negative environmental footprint. However, there are differences in their overall environmental impact.
- Polyester is now widely recycled, especially in the form of PET bottles that can be transformed into fibres for clothing and activewear. The recycling of polyester has helped reduce its overall environmental footprint, although the production of virgin polyester still consumes significant energy and resources. Polyester is not biodegradable, meaning it contributes to long-term waste in landfills and every garment made from polyester has not degraded yet, unlike natural fibres.
- Nylon, while also available as a recycled fibre, nylon is less frequently recycled than polyester. However, there are initiatives to produce nylon from renewable sources (such as castor oil) or to recycle nylon into new fibres. One significant issue with nylon is its environmental persistence; like polyester, it is not biodegradable and can remain in landfills for decades, if not centuries. When it does degrade, the soil it degrades into will then become contaminated with the petrolchemicals.
9. Applications
Both polyester and nylon have a wide range of uses, but each fibre excels in different areas:
- Polyester is commonly used in everyday sportswear or low-cost fashion. It is also widely used in outdoor gear, backpacks, and sleeping bags due to its water-repellent properties. The fibre’s versatility, cost-effectiveness, and resistance to wrinkling make it a staple in many industries.
- Nylon is used in applications that require strength and durability, such as hosiery, lingerie, activewear, ropes, fishing nets, and parachutes. It is also commonly found in technical and outdoor gear, such as tents, backpacks, and outdoor and ski jackets. Nylon’s softness and strength make it an ideal choice for high-performance fabrics.
Conclusion
In the polyester vs. nylon debate, there’s no clear winner—it all comes down to the specific needs and preferences of the user. Polyester offers better moisture-wicking, affordability, and UV resistance, making it ideal for everyday wear, sportswear, and outdoor applications. Nylon, on the other hand, provides superior strength, softness, and abrasion resistance, making it the go-to choice for high-performance gear and technical applications.
Understanding the differences between polyester and nylon will help you make informed decisions when choosing materials for activewear, outdoor gear, sportswear. Whether you prioritise cost, durability, moisture management, or environmental impact, knowing how each fibre performs can guide you to the best option for your needs.
If you need advice on which is the best fibre for your activewear or you want to look at alternatives to these two established staple fibres that are more environmentally friendly, then please get in touch.