Engineering Mechanical-Comfort Trade-Offs in PLA/PET Woven Fabrics for Sustainable Apparel Applications

Polyester (PET) remains one of the most widely used fibers in woven fabrics, yet its non-biodegradable nature raises environmental concerns. To address this challenge, this study evaluates polylactic acid (PLA), a bio-based and biodegradable polymer, as a sustainable alternative to PET in woven textiles. Fabrics were developed using 100% PLA and 100% PET multifilament yarns, along with hybrid combinations of PLA/PET in warp and weft. The yarns were tested for tensile strength, and the woven fabrics were analyzed for mechanical properties (tensile and tear strength) and comfort properties (air permeability, thermal resistance, water vapor permeability, and moisture management). Woven fabrics represent the backbone of global fashion and apparel production, where durability, comfort, and sustainability are equally critical. Results showed that PLA fabrics exhibited superior breathability and moisture transport compared to PET, while maintaining comparable mechanical performance. Unlike previous studies that primarily focused on knitted fabrics or fiber blends, this study establishes a controlled woven-fabric framework that isolates the influence of fiber composition and warp-weft configuration on the balance between mechanical durability and thermo-physiological comfort. These findings highlight the potential of hybrid PLA/PET woven architectures to balance durability and comfort while supporting the broader adoption of sustainable materials in apparel applications.