What Is the Difference Between Polyester Vs Spun Polyester?

Polyester and spun polyester are two variations of the versatile synthetic fiber widely used in the textile industry. While both share the advantages of durability, affordability, and ease of care, they differ in texture, manufacturing process, and properties.

Regular polyester, also known as textured polyester, undergoes a texturizing process that gives it a slightly rougher feel and appearance.

On the other hand, spun polyester is created through a spinning process, resulting in a softer, more fabric-like texture. These differences impact their applications, comfort, and visual appeal.

Understanding the distinctions between polyester and spun polyester helps in making informed choices for various textile and apparel needs.

Key Differences Between Polyester Vs Spun Polyester

Polyester and spun polyester are related but distinct materials with unique characteristics. Here are the key differences between polyester and spun polyester:

Texture

• Polyester: Polyester has a relatively smooth texture. The manufacturing process of regular polyester involves texturizing, which creates a subtle roughness and texture in the fibers. It can resemble natural fibers like cotton or wool, adding depth and visual interest to fabrics.
• Spun Polyester: In contrast, spun polyester has a softer and more fabric-like texture. The spinning process used to produce spun polyester yarn results in intertwined fibers, creating a smoother feel. It is commonly used in apparel manufacturing where comfort and a smooth touch are desired.

Manufacturing Process

• Polyester: The manufacturing process of regular polyester involves extrusion, where polyester fibers are formed into continuous filaments. These filaments are then subjected to various chemical treatments, resulting in a smooth and lustrous appearance. The extruded filaments are subsequently woven or knitted into fabrics.
• Spun Polyester: Spun polyester, on the other hand, undergoes a different manufacturing process known as spinning. In this process, polyester fibers are first extruded into continuous filaments. These filaments are then twisted together, creating a thicker and more yarn-like structure. The twisting action intertwines the fibers, giving spun polyester a softer and more fabric-like texture.

Yarn Thickness

• Polyester: Regular polyester yarn tends to be thinner in comparison. The continuous filaments are often finer, resulting in a lightweight fabric. This characteristic makes regular polyester suitable for applications where a lightweight and breathable material is desired, such as sportswear or summer clothing.
• Spun Polyester: In contrast, spun polyester yarn is generally thicker and more substantial. The twisting of the fibers during the spinning process increases the yarn’s thickness and density. This attribute contributes to the fabric’s weight and durability. Spun polyester is commonly used in garments that require a sturdier and more substantial feel, such as jackets, upholstery, or heavier apparel.

Appearance

• Polyester: Regular polyester has a characteristic shiny and lustrous appearance. The smooth surface of the extruded filaments gives polyester fabrics a glossy finish. This inherent sheen adds a sleek and polished look to garments and textiles.
• Spun Polyester: Spun polyester has a more matte finish compared to regular polyester. The twisted and intertwined fibers create a slightly textured surface that diffuses light, resulting in a softer appearance. This matte finish lends a more natural and fabric-like aesthetic to spun polyester fabrics.

Feel

• Polyester: Regular polyester fabrics have a slightly smooth and slick feel. The extrusion process produces fibers with a smooth surface, resulting in a subtle slippery sensation when touched. While it may not provide the same softness as natural fibers, regular polyester offers a distinct texture that some find appealing.
• Spun Polyester: Spun polyester fabrics offer a softer and more tactile feel. The twisting and intertwining of the fibers during the spinning process create a yarn with a more fabric-like texture. Spun polyester provides a smoother and more comfortable sensation against the skin, making it a popular choice for clothing items that prioritize comfort.

Wrinkle Resistance

• Polyester: Regular polyester exhibits high wrinkle resistance. The synthetic nature of polyester fibers allows them to retain their shape and resist wrinkling even after extended periods of wear or storage. Polyester fabrics tend to maintain a smooth and wrinkle-free appearance, making them ideal for travel or garments that require minimal ironing.
• Spun Polyester: Spun polyester also offers good wrinkle resistance, although it may not be as pronounced as regular polyester. The twisting and intertwining of the fibers provide some structural stability, reducing the likelihood of deep creases or wrinkles. While it may require a bit more care to keep spun polyester garments wrinkle-free, they still offer decent wrinkle resistance compared to other fabric types.

Moisture-Wicking

• Polyester: Polyester fabrics are known for their moisture-wicking properties. The hydrophobic nature of polyester fibers allows them to repel moisture and quickly transport sweat or moisture away from the skin. This wicking action helps keep the wearer dry and comfortable during physical activities or in warm conditions.
• Spun Polyester: Like regular polyester, spun polyester also possesses moisture-wicking capabilities. The inherent properties of polyester fibers enable them to draw moisture away from the body, promoting evaporation and maintaining a drier feel. This moisture-wicking feature makes spun polyester suitable for activewear, athletic apparel, or any application where moisture management is essential.

Quick-Drying

• Polyester: Polyester fabrics excel in quick-drying properties. The hydrophobic nature of polyester fibers prevents them from absorbing excessive moisture, allowing water or sweat to evaporate rapidly. Polyester garments or textiles dry relatively quickly, reducing the time required for laundering or air-drying.
• Spun Polyester: Similarly, spun polyester demonstrates quick-drying capabilities due to its polyester composition. The twisted and compact structure of spun polyester yarn facilitates efficient moisture evaporation, resulting in faster drying times compared to other fabric types. This quick-drying feature is advantageous for outdoor gear, swimwear, or any application where rapid moisture evaporation is desired.

Durability

• Polyester: Polyester is renowned for its durability and robustness. The synthetic fibers exhibit excellent resistance to wear, tear, and abrasion, making polyester fabrics long-lasting. They can withstand frequent laundering, stretching, and general wear, ensuring the longevity of garments and textiles made from polyester.
• Spun Polyester: Spun polyester shares the same durability characteristics as regular polyester. The twisting and intertwining of fibers during the spinning process enhance the fabric’s strength and resilience. Spun polyester fabrics are highly resistant to pilling, fraying, and general wear, making them suitable for applications that demand durability, such as upholstery, outdoor furnishings, or heavy-duty clothing.

Stretchability

• Polyester: Regular polyester has limited stretchability. The fibers possess minimal inherent elasticity, resulting in fabrics that offer little stretch or give. While they can exhibit some degree of flexibility, polyester fabrics are generally more rigid and less stretchy compared to natural fibers like cotton or spandex.
• Spun Polyester: Spun polyester, like regular polyester, has limited stretchability. Although the twisting of fibers provides some flexibility, the overall stretchiness is relatively low. Spun polyester fabrics offer slight give and stretch, but they do not have the same level of elasticity as fabrics containing spandex or elastane.

Shrinkage

• Polyester: Regular polyester is known for its low shrinkage properties. Polyester fibers are highly resistant to shrinking, even when exposed to heat or frequent washing. This makes polyester garments and textiles retain their original size and shape over time, providing consistent fit and appearance.
• Spun Polyester: Spun polyester also exhibits minimal shrinkage. The twisting and intertwining of fibers during the spinning process contribute to the fabric’s stability, reducing the potential for shrinkage. Spun polyester garments maintain their dimensions, ensuring a reliable and consistent fit.

Comfort

• Polyester: Regular polyester fabrics may not provide the same level of comfort as natural fibers. The smooth and slick texture of polyester can feel less breathable against the skin, particularly in warm or humid conditions. However, advancements in polyester manufacturing have led to the development of softer variations that offer improved comfort.
• Spun Polyester: Spun polyester fabrics offer enhanced comfort compared to regular polyester. The softer and more fabric-like texture of spun polyester provides a more pleasant feel against the skin. This makes it a popular choice for apparel where comfort is a priority, such as t-shirts, dresses, or loungewear.

Application

• Polyester: Regular polyester has a wide range of applications. It is commonly used in sportswear, outdoor gear, home furnishings, and various industrial applications. The durability, moisture-wicking properties, and wrinkle resistance of polyester make it suitable for versatile uses across different industries.
• Spun Polyester: Spun polyester finds its primary application in apparel manufacturing. Its softness, fabric-like feel, and comfort make it an ideal choice for garments like t-shirts, dresses, athletic wear, and casual clothing. Spun polyester is also utilized in upholstery, home textiles, and other applications that require a combination of durability and comfort.

Resistance to Fading

• Polyester: Polyester fabrics are highly resistant to fading. The synthetic nature of polyester fibers allows them to retain color vibrancy even after prolonged exposure to sunlight or repeated washing. Polyester garments maintain their original color intensity, providing long-lasting visual appeal.
• Spun Polyester: Spun polyester, similar to regular polyester, exhibits excellent resistance to fading. The colorfastness of spun polyester fabrics ensures that they retain their original colors and vibrancy over time, even with frequent use and exposure to environmental factors like UV radiation.

Resistance to Pilling

• Polyester: Regular polyester fabrics are resistant to pilling. The smooth and tightly woven structure of polyester fibers minimizes the formation of pill balls, ensuring that the fabric’s surface remains smooth and free from unsightly fuzz or abrasions. Polyester garments maintain their appearance and texture over extended periods.
• Spun Polyester: Spun polyester fabrics also offer resistance to pilling. The twisting and intertwining of fibers during the spinning process create a more cohesive fabric structure, reducing the likelihood of pilling. Spun polyester garments maintain their smoothness and visual appeal, even with frequent use and washing.

Care

• Polyester: Regular polyester is easy to care for. It is machine washable and can withstand regular laundering without losing its shape or color. Polyester fabrics are generally low maintenance and require minimal ironing. They also have good resistance to shrinking and stretching, allowing for long-term durability and easy care.
• Spun Polyester: Spun polyester is also easy to care for. It can be machine washed and dried without significant shrinkage or damage. Like regular polyester, spun polyester fabrics have excellent resistance to wrinkling, reducing the need for ironing or steaming. The durability of spun polyester ensures that it retains its shape and appearance even with regular washing and wear.

Cost

• Polyester: Regular polyester is known for its affordability. As a synthetic fiber, polyester is generally less expensive to produce compared to natural fibers. This cost-effectiveness makes polyester a popular choice in a wide range of applications, from clothing to home furnishings, where budget considerations are important.
• Spun Polyester: Spun polyester is also cost-effective. While it may have a slightly higher price point compared to regular polyester due to the additional processing involved in spinning, spun polyester remains a cost-efficient alternative to natural fibers. It offers similar benefits and durability at a relatively affordable price, making it a practical choice for various applications.

Availability

• Polyester: Regular polyester is widely available in the market. It is a popular and commonly used synthetic fiber, so polyester fabrics and products can be found in a wide range of stores and online retailers. Polyester’s availability makes it easily accessible for both consumers and manufacturers.
• Spun Polyester: Spun polyester is also readily available. While it may not be as prevalent as regular polyester, spun polyester fabrics and products can still be found in many textile and apparel stores. It is commonly stocked by manufacturers and suppliers, ensuring a reasonable level of availability for those seeking spun polyester materials.

Visual Interest

• Polyester: Regular polyester fabrics offer a smooth and lustrous appearance. They can have a sleek and shiny finish, adding a touch of elegance to garments and textiles. While the visual interest may not come from texture, polyester fabrics often showcase vibrant colors and patterns, making them visually appealing in their own right.
• Spun Polyester: Spun polyester fabrics provide visual interest through texture. The twisting and intertwining of fibers during the spinning process create a natural, textured look. This texture adds depth and dimension to fabrics, making them visually intriguing. Spun polyester fabrics can have a more organic and tactile aesthetic compared to regular polyester.

Weight

• Polyester: Regular polyester fabrics tend to be lightweight. The thin and fine fibers used in polyester production contribute to a lightweight feel, making it suitable for applications where a lightweight and breathable material is desired. Polyester’s lightweight nature allows for comfortable wear and ease of movement.
• Spun Polyester: Spun polyester fabrics have a moderate weight. The twisting and intertwining of fibers during the spinning process result in a slightly thicker and denser fabric compared to regular polyester. While not as heavy as some natural fibers, spun polyester provides a substantial feel, making it suitable for applications where a more substantial weight is desired, such as jackets or upholstery.

Versatility

• Polyester: Regular polyester is highly versatile and can be used in various applications. It is commonly found in sportswear, outdoor gear, home furnishings, and industrial applications. Polyester’s versatility stems from its durability, moisture-wicking properties, and resistance to wrinkling, making it suitable for a wide range of uses across different industries.
• Spun Polyester: Spun polyester is also versatile, particularly in the realm of apparel manufacturing. Its softness, fabric-like texture, and comfort make it an excellent choice for garments like t-shirts, dresses, and casual wear. Spun polyester’s versatility extends to upholstery, home textiles, and other applications that require a combination of durability and comfort.

Color Retention

• Polyester: Polyester fabrics are known for their excellent color retention. The synthetic nature of polyester fibers allows them to retain their vibrant hues even after repeated washing or exposure to sunlight. Polyester garments maintain their color intensity, ensuring long-lasting visual appeal.
• Spun Polyester: Spun polyester also exhibits remarkable color retention. The colorfastness of spun polyester fabrics ensures that they retain their original colors and vibrancy even with frequent use and exposure to environmental factors. The colors of spun polyester garments remain vivid and attractive over time.

Environmental Impact

• Polyester: Regular polyester has a relatively higher environmental impact compared to natural fibers. It is a synthetic fiber derived from petrochemicals, making its production energy-intensive and reliant on fossil fuels. Additionally, polyester is not biodegradable, contributing to microplastic pollution when garments eventually break down.
• Spun Polyester: Spun polyester shares the same environmental impact as regular polyester. The manufacturing process and composition of spun polyester involve the use of synthetic materials and energy-intensive processes. However, efforts are being made in the textile industry to increase the use of recycled polyester, which can help mitigate the environmental impact of spun polyester.

Wrinkle Recovery

• Polyester: Regular polyester fabrics have good wrinkle recovery properties. Even if they do wrinkle, wrinkles in polyester garments are usually easy to remove through simple methods such as hanging or steaming. Polyester’s resilience allows garments to bounce back to their smooth and wrinkle-free state with minimal effort.
• Spun Polyester: Spun polyester also demonstrates good wrinkle recovery. While it may not have the same wrinkle resistance as regular polyester, spun polyester fabrics can regain their smooth appearance relatively quickly. Wrinkles in spun polyester garments can often be eliminated by hanging or steaming, ensuring a neat and polished look.

Crease Resistance

• Polyester: Regular polyester fabrics have limited crease resistance. Although they are generally resistant to wrinkling, polyester can still develop creases when folded or packed tightly. However, creases in polyester garments can be easily smoothed out with minimal effort, restoring the fabric to its original state.
• Spun Polyester: Spun polyester fabrics also offer limited crease resistance. While they may develop creases when folded or stored, the twisting and intertwining of fibers provide some resilience against deep creases. Spun polyester garments can be easily smoothed out, minimizing the appearance of creases and maintaining a tidy look.

Polyester Vs Spun Polyester: Comparison Table

Aspect	Polyester	Spun Polyester
Texture	Relatively smooth	Softer and fabric-like
Manufacturing Process	Extrusion and spinning	Spinning
Yarn Thickness	Thinner yarn	Thicker yarn
Appearance	Shiny and lustrous	Matte finish
Feel	Slightly rough	Smoother
Wrinkle Resistance	Highly wrinkle-resistant	Resistant to wrinkles
Moisture-Wicking	Yes	Yes
Quick-Drying	Yes	Yes
Durability	Highly durable	Highly durable
Stretchability	Limited stretch	Limited stretch
Shrinkage	Less prone to shrinkage	Less prone to shrinkage
Comfort	Less fabric-like feel	More fabric-like feel
Application	Sportswear, outdoor gear, home furnishings	Apparel, t-shirts, dresses, casual wear
Resistance to Fading	Resistant	Resistant
Resistance to Pilling	Resistant	Resistant
Care	Easy to care for	Easy to care for
Cost	Affordable	Affordable
Availability	Widely available	Widely available
Visual Interest	Smooth appearance	Natural, textured look
Weight	Lightweight	Moderate weight
Versatility	Versatile	Versatile
Color Retention	Good color retention	Good color retention
Environmental Impact	Synthetic fiber	Synthetic fiber
Wrinkle Recovery	Good wrinkle recovery	Good wrinkle recovery
Crease Resistance	Limited crease resistance	Limited crease resistance

Frequently Asked Questions

To Recap

Polyester and spun polyester offer distinct qualities that cater to different preferences and applications. Regular polyester provides a smooth and lustrous appearance with good wrinkle resistance, making it suitable for sportswear, outdoor gear, and home furnishings.

Spun polyester, with its softer texture and fabric-like feel, excels in comfort and is often chosen for apparel such as t-shirts, dresses, and casual wear. Both polyester variations exhibit excellent durability, moisture-wicking properties, and color retention.

However, it’s important to consider the environmental impact of synthetic fibers. By understanding their characteristics, individuals can make informed decisions when selecting between polyester and spun polyester for their specific needs.