In the highly competitive world of activewear, comfort is king. For brands that prioritize both performance and luxury, fabric handfeel can be the game-changer. That’s why more designers and buyers—especially those catering to U.S. and European fitness consumers—are turning to double-brushed polyester. It’s soft, durable, stretch-friendly, and perfect for all-day wear.
Double-brushed polyester provides a velvety, soft handfeel on both sides of the fabric, while maintaining durability, moisture control, and shape retention—making it ideal for leggings, yoga tops, and gym sets. For activewear brands seeking tactile appeal and lasting performance, this fabric has become a go-to material.
In this article, I’ll explain what double-brushed polyester is, how it’s made, and why it’s loved by both premium fitness labels and fast-growing e-commerce brands.
What Is Double-Brushed Polyester and How Is It Made?
Brushed polyester is a synthetic knit fabric that undergoes mechanical brushing to lift the microfibers, creating a suede-like surface. When both the face and back are brushed, you get double-brushed polyester—a fabric that feels plush, warm, and gentle against the skin.
Double-brushed polyester is made by mechanically treating both sides of the knit fabric to raise tiny fibers, which increases softness, warmth, and tactile appeal without compromising stretch or resilience.
How Is Double Brushing Performed in Fabric Finishing?
The brushing process uses metal rollers with tiny needles or wire loops. These rollers comb the fabric’s surface in a controlled manner. The result is a soft nap on both the front and back of the fabric.
According to Textile School, brushing increases surface area and fiber density, enhancing thermal properties and softness. FabricLink also highlights brushing as a finishing process often applied to polyester to emulate the feel of cotton or fleece.
What Makes It Different from Single-Brushed Polyester?
Single-brushed polyester only has the brushed surface on one side—usually the inner side. It’s still comfortable but lacks the uniform softness and elevated handfeel of double-brushed types. For items like leggings, where both sides touch the skin, double-brushed is the clear winner.
Why Is Double-Brushed Polyester Perfect for Activewear?
Comfort and performance are the foundation of good activewear. Double-brushed polyester not only feels incredibly soft but also performs well in dynamic movement.
This fabric offers four-way stretch, moisture-wicking capability, and abrasion resistance—while maintaining a luxurious feel that consumers associate with higher-end gym apparel.
Is It Stretchy Enough for Yoga and Compression Fit?
Yes. Most double-brushed polyester blends include spandex or elastane—giving the fabric excellent stretch and recovery. This is why many brands use it for yoga leggings, squat-proof workout bottoms, and fitted tops.
Retailers like Alphalete and Colorfulkoala use DBP (double-brushed poly) in their core leggings lines because it provides buttery softness without sacrificing fit integrity.
How Does It Hold Up Against Sweat and Motion?
Polyester fibers are inherently moisture-wicking and quick-drying. When brushed, they retain warmth but still allow breathability—especially when used in lighter GSM weights.
Moisture Management Textile Testing like AATCC TM195 confirms that brushed poly blends can perform at par with technical knits. Brands using DBP often report low odor retention and better comfort during long workouts.
What Are the Advantages Over Cotton or Nylon Fabrics?
While cotton may feel soft at first, it lacks elasticity and moisture control. Nylon is slick and durable, but can feel cold and less inviting. Double-brushed polyester strikes the ideal balance between tactile appeal and function.
Compared to cotton and nylon, double-brushed polyester offers superior softness, faster dry time, and higher elasticity—making it more suitable for modern fitness lifestyles.
Why Do Consumers Prefer DBP Over Cotton?
Cotton absorbs sweat, becomes heavy, and loses shape over time. DBP, on the other hand, remains lightweight and retains its softness even after repeated washes.
Online reviews from Amazon and Etsy show a strong preference for leggings and tops that feel “like a second skin.” This consistent softness, even under pressure, is why DBP has a high return buyer rate.
What About Nylon-Spandex Performance?
Nylon is durable and often used in compression or high-impact garments. But it's not as cozy. DBP feels warmer and more inviting, especially in cooler climates or indoor workouts. According to Spoonflower, DBP is one of their top sellers for custom leggings due to its rich handfeel and stretch.
How to Source Reliable Double-Brushed Polyester for Your Brand?
Not all DBP fabrics are created equal. Some mills cut corners on brushing, or use low-grade polyester yarns. That’s why sourcing from experienced mills with lab-tested product lines is crucial.
Look for suppliers that offer GSM flexibility, elastane blends, and CNAS/SGS test reports verifying colorfastness, pilling resistance, and softness grade.
What Specs Should You Ask For?
- GSM range: Commonly 180–230 GSM for leggings and tops
- Stretch ratio: At least 4-way with 10–20% spandex
- Test results: Pilling (ASTM D4970), colorfastness (ISO 105), softness index (internal scale)
We at Fumao Fabric offer double-brushed polyester with consistent brushing quality, OEKO-TEX compliance, and custom print or dyeing services for private label buyers.
Where Can I Find DBP Fabric in Bulk?
Besides Alibaba or domestic wholesalers, look for suppliers who specialize in performance fabrics. Trade shows like ISPO or Performance Days are great places to test swatches and feel the softness firsthand.
We also provide QR-coded inventory data and lab dip verification for e-commerce brands that need fast, accurate restocks on DBP lines.
Conclusion
Double-brushed polyester isn’t just a trending material—it’s a game-changing choice for activewear brands seeking to combine softness, durability, and technical performance. From buttery yoga leggings to soft-touch gym tops, DBP delivers what modern consumers demand. When sourced properly from mills like ours at Fumao Fabric, you can ensure consistent handfeel, premium quality, and supply chain transparency—all in one fabric solution.
