Investigate the varying ratios of different PCM types on uniform characteristics produced with polyester double-woven fabric

Abstract Phase Change Materials (PCMs) offer promising thermoregulation for functional uniforms, but optimal integration strategies balancing performance and cost remain unclear. This study systematically investigates how PCM type and blending ratio affect polyester double-woven fabric properties for uniform applications. We manufactured 12 fabric samples varying: (1) PCM type (polyester-based vs. viscose-based), (2) blending ratios (25%, 50%, 75% PCM content), and (3) carrier yarn (microfiber vs. Renova®). Comprehensive characterization included mechanical testing (tensile strength, stiffness), thermal analysis (DSC, thermal conductivity), comfort evaluation (air/water permeability, moisture management), and protective performance (UPF, electrostatic charge). Statistical significance was validated via two-way ANOVA (95% confidence, P ≤ 0.05), including interaction effects, and multi-criteria radar chart optimization. Results demonstrate that viscose-based PCMs significantly outperformed polyester-based alternatives, achieving 33% higher thermal storage capacity (46.86 J/m 2 vs. 35.20 J/m 2 at 75:25 blending ratio), 65–100% reduction in electrostatic charge (viscose-based: 0–0.013 kV vs. polyester-based: 0.003–0.037 kV), and superior hydrophilic properties enhancing moisture management. Critically, the 50% PCM: 50% Polyester Microfiber blending ratio (with viscose-based PCM) emerged as the optimal composition, maximizing thermal regulation, while maintaining mechanical and achieving excellent UV protection (UPF > 50+). ANOVA confirmed statistically significant main effects for 12/14 parameters ( P ≤ 0.05) and revealed critical interaction effects (Weft Material Type × Blending Ratio) for mechanical, comfort, and protective properties, whereas thermal storage capacity responded independently to these factors. These findings provide actionable design guidelines for material-efficient production of high-performance uniform fabrics, demonstrating that strategic PCM selection and a 50% blending ratio can simultaneously enhance thermal comfort, reduce static-related safety hazards, and maintain protective functionality while optimizing the proportion of functional PCM yarns—directly addressing conflicting requirements in professional workwear applications across industrial, medical, and service sectors.