Polyester vs Nylon for Activewear: Technical Comparison

Polyester and nylon dominate synthetic activewear fabrics, but which is better? The answer depends on your priorities: cost-effectiveness, hand feel, specific performance needs, and market positioning.

Chemical and Physical Properties

Polyester (PET - Polyethylene Terephthalate)

Chemical Structure: Ester linkages between repeating units Source: Petroleum-derived (or recycled PET bottles)

Physical Properties:

• Specific gravity: 1.38
• Moisture regain: <0.4%
• Melting point: 255-260°C
• Tensile strength: Good
• Abrasion resistance: Good

Nylon (Polyamide)

Chemical Structure: Amide linkages between repeating units Source: Petroleum-derived Types: Nylon 6, Nylon 6.6 most common

Physical Properties:

• Specific gravity: 1.14 (lighter than polyester)
• Moisture regain: 4.0-4.5% (absorbs some moisture)
• Melting point: 215-220°C (lower than polyester)
• Tensile strength: Excellent (strongest synthetic)
• Abrasion resistance: Excellent (best synthetic)

Head-to-Head Comparison

Detailed Property Analysis

Moisture Management

Polyester:

• Hydrophobic (water-repelling)
• Moisture regain: <0.4%
• Wicks moisture to surface
• Stays dry during activity
• Dries in 2-3 hours

Nylon:

• Slightly hydrophilic (absorbs ~4% moisture)
• Still wicks well (better than cotton)
• Feels slightly damp when wet
• Dries in 3-4 hours

Winner: Polyester for pure moisture management

Application:

• Hot yoga: Polyester preferred
• Running in heat: Polyester preferred
• General gym: Either works well

Strength and Durability

Tensile Strength:

• Nylon: ~20% stronger than polyester
• Both excellent for activewear

Abrasion Resistance:

• Nylon: Superior (30-40% better)
• Polyester: Good

Practical Impact:

• Nylon better for: Yoga pants (friction on mats/floors), climbing wear, high-abrasion applications
• Polyester adequate for: Most activewear, tops, shorts

Winner: Nylon for maximum durability

Hand Feel and Comfort

Nylon:

• Naturally softer, smoother
• Silkier hand feel
• "Buttery soft" easier to achieve
• Premium tactile experience

Polyester:

• Modern polyester very soft (technology improved)
• Cotton-like modifications available
• Slightly more "technical" feel
• Still comfortable

Winner: Nylon for hand feel

Market Impact:

• Premium yoga wear: Nylon preferred (HD8578: 80/20 Nylon/Spandex)
• Performance sportswear: Polyester acceptable
• Luxury activewear: Nylon commands premium

Cost Analysis

Raw Material Cost (2026):

• Polyester: Baseline
• Nylon: +20-35% cost

Fabric Cost Example (FOB China):

• Polyester/Spandex (85/15, 200gsm): $3.50-4.00/meter
• Nylon/Spandex (80/20, 210gsm): $4.50-6.00/meter

Retail Impact:

• Polyester leggings: $40-70 retail
• Nylon leggings: $70-120 retail

Winner: Polyester for cost-effectiveness

UV and Chemical Resistance

UV Resistance:

• Polyester: Excellent (minimal degradation)
• Nylon: Fair (degrades faster in sunlight)

Chlorine Resistance:

• Polyester: Excellent (pool/hot tub suitable)
• Nylon: Poor (yellows, loses strength)

Winner: Polyester for outdoor/pool use

Application:

• Outdoor running: Polyester better
• Swimwear: Polyester essential
• Indoor yoga: Either works

Environmental Considerations

Recycling:

• Polyester: Widely recyclable (rPET from bottles)
• Nylon: Recycling emerging but less established

Sustainability:

• Recycled polyester widely available
• Recycled nylon (Econyl) growing but limited

Biodegradability:

• Neither biodegrades (both synthetic)

Winner: Polyester (recycling infrastructure)

When to Choose Polyester

Ideal Applications:

1. Running and High-Intensity Sports

   • Maximum moisture-wicking critical
   • Quick-dry important
   • Cost-effective for volume

2. Hot Yoga

   • Moisture management priority
   • Quick-drying essential
   • Chlorine resistance (some studios use pools)

3. Swimwear/Pool Activities

   • Chlorine resistance essential
   • UV resistance important

4. Budget/Value-Oriented Brands

   • Lower cost enables competitive pricing
   • Good performance at accessible price

5. Outdoor Activewear

   • UV resistance matters
   • All-weather performance

Huada Polyester Products: All Huada products are polyester-based, optimized for activewear performance at accessible pricing.

When to Choose Nylon

Ideal Applications:

1. Premium Yoga Wear

   • Soft hand feel priority
   • Luxury positioning
   • Customers willing to pay premium

2. Leggings (High-End)

   • Superior abrasion resistance (mat/floor friction)
   • Buttery soft feel
   • Premium market ($80-120 retail)

3. Activewear with High Abrasion

   • Climbing pants
   • High-friction areas
   • Maximum durability needed

4. Luxury Athleisure

   • Premium soft aesthetic
   • High-end market positioning
   • Elevated tactile experience

Huada Nylon Product: HD8578 Lycra Yoga Fabric (210gsm, 80% Nylon / 20% Spandex)

• Premium buttery-soft feel
• Excellent for high-end yoga wear
• Superior hand feel
• Justifies premium pricing

Blends and Combinations

Polyester/Nylon Blends: Rare in activewear; typically one or the other

Both with Spandex:

• Polyester/Spandex: 85/15, 80/20 typical
• Nylon/Spandex: 80/20, 75/25 typical

Cost-Benefit Analysis

Scenario: 1,000 Yoga Pants

Option A: Polyester/Spandex (85/15, 220gsm)

• Fabric: $3.80/meter
• Cost per pant: ~$2.50
• Total fabric cost: $2,500
• Retail price: $50-70
• Positioning: Mid-market

Option B: Nylon/Spandex (80/20, 210gsm - HD8578)

• Fabric: $5.20/meter
• Cost per pant: ~$3.40
• Total fabric cost: $3,400
• Retail price: $80-120
• Positioning: Premium

Analysis:

• Extra $900 fabric cost
• Enables $30-50 higher retail price
• Profit increase: $29,100-49,100 (on 1,000 units)
• ROI on premium fabric: 3,200-5,400%

Conclusion: Nylon investment justified for premium positioning

Consumer Perception

Survey Data (Activewear Purchasers):

• Can feel difference between nylon/polyester: 68%
• Willing to pay premium for nylon: 52%
• Prioritize performance over feel: 47%
• Prioritize feel over performance: 38%

Interpretation:

• Nylon's soft feel is perceivable value-add
• Premium pricing supported by consumer preference
• Performance-focused segment still large (polyester)

Conclusion

Polyester excels in moisture-wicking, quick-drying, UV/chlorine resistance, and cost-effectiveness—ideal for performance sportswear, running, hot yoga, and value-oriented brands. Nylon offers superior softness, strength, and abrasion resistance—perfect for premium yoga wear, luxury athleisure, and high-end leggings.

Key Takeaways:

1. Polyester for performance & value - Better moisture management, lower cost
2. Nylon for premium feel - Softer, justifies higher pricing
3. Moisture-wicking: Polyester wins - Lower moisture regain
4. Hand feel: Nylon wins - Naturally softer
5. Cost: Polyester 20-35% cheaper - Enables competitive pricing
6. Premium positioning: Nylon enables $30-50 higher retail - ROI justified

At Huada Creation, we offer both: polyester-based fabrics across our range for performance and value, plus HD8578 Lycra Yoga (80/20 Nylon/Spandex) for brands targeting the premium yoga market.

Compare Options:

• HD8193 Anta Stretch (Polyester/Spandex) - Performance value
• HD8578 Lycra Yoga (Nylon/Spandex) - Premium soft
• View All Fabrics