Polyester vs Nylon for Leggings: Lab Data from a 20-Year Factory

# Polyester vs Nylon for Leggings: Which Fabric Wins on Cost, Stretch, and Durability? You’ve got a leggings line in the works. The fabric spec sheet is on your desk, but the landed-cost difference between polyester and nylon has you stuck. Maybe you’re worried about sampling delays (will it take three weeks just to see a swatch?) or whether a minimum order quantity of 500 pieces will blow your startup budget. We’ve been on the factory floor in Zhejiang for 20+ years, and we see this decision every week. Here’s the raw data from our fabric library—no fluff, just numbers you can use to make a call today. ## Fiber basics Let’s start with what’s actually in the yarn—because a leggings fabric is only as good as its base fiber. Polyester (PET) is a synthetic polymer made from ethylene glycol and terephthalic acid. Nylon (polyamide) is made from petroleum-based monomers, but its molecular structure gives it a different hand feel and mechanical profile. On our floor, we source both in deniers ranging from 20D to 150D, depending on the end use. **Polyester** – We use mainly recycled polyester (rPET) for our leggings lines, but virgin polyester is also available. Typical filament count: 48f to 72f for a soft hand. GSM range in our library: 150 to 220 for leggings. The fiber is hydrophobic, so it dries fast and doesn’t absorb sweat. That’s why it’s the default for high-intensity running and training leggings. However, because it’s less elastic by nature, we often blend it with 10–20% spandex (elastane) to get the four-way stretch buyers expect. **Nylon** – We stock nylon 6 and nylon 6,6. Nylon 6,6 is more abrasion-resistant and holds its shape better, but it costs about 15–20% more per kilogram. For leggings, we typically use 40D–70D nylon with 15–25% spandex. GSM in our library: 180–240. Nylon is hydrophilic, so it feels softer against the skin and has a natural “silk” hand. But it absorbs moisture, which can lead to clinging during heavy sweat sessions. Our QC team measures moisture regain: nylon ~4%, polyester ~0.4%. Both fibers can be solution-dyed or piece-dyed. We offer Pantone matching on almost any color—just send us a reference. For polyester, we use disperse dyes; for nylon, acid dyes. The dyeing process for nylon is more temperature-sensitive, which adds about 2–3 days to our lead time for custom colors. But we still ship samples in 3–7 days, even for nylon. ## Performance comparison table Here is the data from our lab tests on three representative fabrics from our library. All samples are 75D/36f with 15% spandex for a fair comparison. We test every batch before production. The numbers below are averages from our last 12 months of QC records. | Property | Polyester (75D/36f + 15% Spandex) | Nylon 6,6 (70D/48f + 20% Spandex) | Nylon 6 (70D/48f + 18% Spandex) | |----------|-----------------------------------|------------------------------------|----------------------------------| | GSM (g/m²) | 185 ± 5 | 210 ± 8 | 205 ± 6 | | 4-Way Stretch (%) | 180% warp, 190% weft | 200% warp, 210% weft | 195% warp, 205% weft | | Pilling (Martindale, cycles to pill) | 8,000 – 12,000 | 15,000 – 20,000 | 12,000 – 16,000 | | Tensile Strength (N) | 350 – 400 | 450 – 500 | 400 – 450 | | Moisture Wicking (seconds) | 2 – 3 (rapid) | 6 – 8 (moderate) | 7 – 10 (slow) | | Cost per yard (FOB Zhejiang, USD) | $3.50 – $5.00 | $5.50 – $8.00 | $5.00 – $7.00 | | Recommended Spandex Blending | 10–20% | 15–25% | 15–25% | **Key takeaway:** Nylon (especially 6,6) outperforms polyester on stretch and pilling resistance, but it’s heavier (higher GSM) and costs 40–60% more per yard. Polyester wins on price, moisture wicking, and lighter weight. There is no single “best” fiber—it depends on your product’s price point and performance target. ## Cost & MOQ impact When you’re a buyer—whether a brand founder, gym owner, or Amazon seller—the cost per unit is only part of the equation. You also have to factor in MOQ, sampling fees, and lead time. Our factory has no minimum order quantity. We can produce a single piece for you. Seriously. We’ve done one-off samples for a startup that wanted to test the market before committing to 300 units. Here’s how the numbers break down for polyester vs nylon leggings. **Sampling cost:** A sample pair of polyester leggings (custom color, your logo, your size) costs $25–$35 per piece, including fabric and trim. Nylon samples run $35–$50 because the fabric is pricier and the dyeing process takes longer. We ship samples in 3–7 days via DHL or FedEx. **Bulk pricing (FOB):** Polyester leggings (150–220 GSM, 4-way stretch, with logo) in a 300-piece order: $6.50–$9.00 per unit depending on features (zipper pockets, waistband elastic, reflective piping). Nylon leggings of similar construction: $9.00–$13.00 per unit. The price gap narrows as volume increases. At 1,000 pieces, polyester drops to $5.50–$7.50, nylon to $8.00–$11.00. **Lead time:** After sample approval, a 300-piece order of polyester leggings takes 4–6 weeks. Nylon takes 5–7 weeks because of the longer dyeing and finishing cycle. For rush orders, we can compress to 3–4 weeks on polyester, but nylon dyeing doesn’t accelerate well—the risk of color variation rises. **MOQ impact:** Because we have no MOQ, you can order just 50 pieces of nylon leggings for a test run. But the per-unit cost will be higher (around $12–$15). We often advise buyers to start with polyester for initial runs, validate the market, then switch to nylon for a premium line. Our [private label activewear](/private-label-activewear) service includes both fibers, and we can help you price the two options side by side. **Hidden costs:** Nylon is more prone to snagging during sewing, so our QC team spends more time on inspection. That adds about 2–3% to the labor cost. We also recommend anti-pilling finishes for nylon, which adds $0.30–$0.50 per garment. Polyester typically doesn’t need that treatment. ## Which to pick per product The right fiber depends on what your customers will do in those leggings. Here’s our rule of thumb, based on orders we’ve shipped to gyms, yoga studios, and Amazon sellers. - **Yoga and Pilates Leggings** – Go with nylon. The soft hand feel, higher stretch, and better recovery (it returns to shape faster) matter when customers are bending and stretching. Nylon also drapes better, which reduces the “sausage casing” look. Check our [yoga wear wholesale guide](/pages/yoga-wear-wholesale-guide) for more details on blends and finishes. - **Running and High-Intensity Training Leggings** – Polyester is the workhorse. It dries fast, wicks sweat, and keeps the garment light. A 150 GSM polyester with 15% spandex is ideal for summer runs. We have a specific [running wear wholesale guide](/pages/running-wear-wholesale-guide) that covers ventilation panels and reflective details. - **Compression Tights** – Nylon 6,6 is the best choice for compression because it has higher tensile strength and can hold tighter knit structures without losing elasticity. Our [compression shirts](/pages/compression-shirts) line uses the same fabric logic. For compression leggings, we recommend 200–230 GSM nylon with 20–25% spandex. - **Everyday Athleisure** – A polyester-nylon blend (50/50 or 60/40) balances cost and feel. We can custom blend on our knitting machines. The blend typically costs $4.50–$6.00 per yard, right in the middle. We’ve done this for several [low MOQ sportswear](/low-moq-sportswear) startups. - **Amazon FBA Sellers** – If you are selling on Amazon, polyester is usually the safer bet because the lower cost per unit gives you more margin to absorb PPC and returns. Plus, polyester’s colorfastness helps with fewer returns from fading. We can apply FBA labels directly in our factory and ship to Amazon warehouses. See our [wholesale sportswear](/wholesale-sportswear) page for FBA-ready packaging. ## FAQ **Which feels more premium?** Nylon, hands down. The fiber has a natural softness and a silky hand feel that polyester can’t replicate without special finishes. In blind tests, 8 out of 10 of our clients prefer the touch of nylon for leggings. However, after a few washes, the difference narrows—polyester with a brushed finish can feel close. **Which lasts longer?** Nylon 6,6 has the highest abrasion resistance—it can withstand 15,000+ Martindale cycles before pilling, compared to 8,000–12,000 for polyester. But nylon degrades faster under UV light (sunlight) and can yellow over time if not properly stabilized. Polyester holds its color and shape better after 50+ washes. For leggings that are worn in the gym or outdoors, polyester is more durable over the long term. For yoga or indoor use, nylon wins. **Can I get samples in both fibers for the same design?** Yes. Send us your design and size specs. We’ll produce one sample in polyester and one in nylon. Each sample takes 3–7 days, and we’ll ship both together. We can also include a cost breakdown for bulk orders. **What about sustainability?** We offer recycled polyester (rPET) from post-consumer bottles. Recycled nylon is available but at a higher cost (add $1.00–$1.50 per yard). We don’t fabricate certifications—we can provide a certificate of origin and material composition if needed. --- **Ready to compare polyester and nylon for your leggings line?** We’ll send you swatches, a sample, and a custom quote within 24 hours. [Request a Quote](mailto:support@alpinario.com)