Teijin Frontier Develops Stretch Polyester Yarn for Recyclable Sportswear Applications

New filament aims to replace polyurethane fibres while enabling 100% polyester textile solutions

Teijin Frontier has introduced a new stretch polyester yarn designed for use in sportswear and other apparel applications. The development focuses on enabling fully polyester-based fabrics with stretch functionality. The yarn is positioned as an alternative to conventional polyurethane-based elastic fibres.

Teijin Frontier has announced the development of a stretch polyester yarn intended for use in recyclable sportswear and apparel. The company states that its proprietary polymer design and spinning technology allow the yarn to achieve “excellent elasticity” and stretch recovery.

The yarn is designed to enable the production of “all-polyester fabrics” that are compatible with high-performance polyester materials. It is being positioned as a substitute for polyurethane-based elastic fibres, which are commonly used to provide stretch in sportswear and everyday garments.

According to the company, the new polyester filament is compatible with existing polyester materials, addressing challenges related to differences in heat-setting characteristics between polyester and polyurethane. These differences have previously limited product development when combining elastic and polyester fibres.

Teijin Frontier reports that the yarn retains key performance features associated with high-performance polyesters, including moisture absorption, quick drying, and durable water repellence.

“The strong compatibility between the new stretch polyester yarn and high-performance polyester materials makes it possible to develop 100% polyester textiles that maintain the advanced functions of the polyester material,” the company says.

The company also highlights that the use of a single material composition improves recyclability compared to polyester-polyurethane blends.

The yarn’s elasticity is achieved through polymer design and spinning processes, rather than structural techniques such as combining polymers with different heat-shrinkage properties or using highly crimped yarns. Teijin Frontier states that this method delivers stretch and recovery characteristics comparable to polyurethane-based fibres.

The yarn is also described as having suitable heat-setting properties, allowing its use in the development of stretch textiles for various apparel categories.

“Using the new polyester stretch yarn with high-performance polyester materials will create a 100% polyester textile, making easier recycling possible,” states Teijin Frontier.

The company plans to apply the yarn in sportswear, casual wear, and innerwear. Commercialisation is expected to begin in 2027 in both domestic and international markets. Teijin Frontier has set a target of 100,000 metres of textiles in the initial year, increasing to 500,000 metres by fiscal 2029.

Earlier in the year, Teijin Frontier also developed a multi-functional textile for sports and outdoor apparel as part of its ongoing work in performance materials.