If you’re a gym-goer, you’re likely familiar with Lycra. This fabric has long been a favorite in sports and activewear due to its exceptional elasticity, durability, and moisture-wicking capabilities. Lycra, also known as spandex or elastane, stretches up to eight times its original length, perfect for the garments that require flexibility and comfort essential for activities like weightlifting, yoga, and high-intensity workouts.

Let’s follow our guide to Lycra fabric, and understand its unique features and benefits and why it’s an innovative, functional, popular choice for textiles.

 

What is Lycra fabric?? Is it the Same as Spandex?

Lycra fabric, a synthetic, elastic fiber, is known for its unparalleled stretch, resilience, and versatility in activewear, swimwear, and sportswear. 

Some may wonder if Lycra is the same as spandex—the answer is yes. Lycra, spandex, and elastane are all names for the same elastomeric polyurethane fiber, providing flexibility, durability, and shape retention. 

Lycra is actually the trademarked brand name used exclusively by The LYCRA Company. While Lycra, spandex, and elastane are interchangeable terms, LYCRA® fiber stands out for its quality assurance. This fabric is crafted from elastomeric polyurethane, allowing it to stretch up to eight times its original size without losing shape, offering garments excellent flexibility, durability, and shape retention over time.

 

History and origin of Lycra fabric

Lycra fabric was developed in the late 1950s by the DuPont chemist Joseph Shivers, who sought to create a synthetic fiber with greater stretch and resilience than rubber. Originally intended to replace rubber in restrictive garments like girdles, Lycra quickly gained popularity due to its elasticity, durability, and lightweight nature. 

In 1962, Lycra was introduced to the market and soon became a preferred material in activewear, swimwear, and other form-fitting apparel. This invention revolutionized the textile industry, enabling the creation of comfortable, flexible, and long-lasting garments. Today, Lycra remains a top choice for clothing that demands stretch, comfort, and durability.

 

How stretchable is Lycra fabric?

Lycra fabric is known for its exceptional stretch, capable of expanding up to five to eight times its original size while effortlessly snapping back to its initial shape. This elasticity is the result of Lycra fiber’s unique molecular structure, which allows it to offer unparalleled flexibility without compromising support. Below are its other key advantages.

 

Key advantages of Lycra fabric

Lycra fabric offers numerous advantages, making it a preferred choice in activewear, swimwear, shirts, clothes, and other apparel. Here are its key benefits:

Exceptional Stretchability: As mentioned above, Lycra can stretch up to 5 to 8 times of its original size and recover its shape, making it ideal for form-fitting clothing such as leggings, yoga pants, compression shorts, bodysuits, and swimwear.

Shape Retention: It maintains its shape even after repeated use, ensuring a snug fit for garments like sports bras, tights, and shapewear.

Durability: Lycra fabric is resistant to abrasion, allowing it to withstand rigorous wear and wash cycles, which makes it popular in high-performance sportswear that is often stained with sweat.

Moisture-Wicking: It quickly absorbs and evaporates moisture, keeping the wearer dry during intense activities, ideal for gym wear and intense sports.

UV and Chlorine Resistance: Lycra is resistant to UV rays and chlorine, making it perfect for swimwear, as it retains color and elasticity in water.

 

Limitations of Lycra fabric

While Lycra fabric offers many benefits, it also has some limitations that can impact its suitability in various applications:

Synthetic origin & non-biodegradable: Lycra is made from petrochemical-derived polymers, which are non-renewable. Its production relies on non-sustainable resources, making it less eco-friendly compared to natural fibers like cotton or wool. 

Chemical-intensive production: The manufacturing of Lycra involves various chemicals and solvents, which, if not managed properly, can pose environmental hazards.

Heat sensitivity: Lycra is sensitive to high temperature, which can break down its elasticity over time. High heat from washing, drying, or ironing can damage Lycra fibers, making the fabric lose its stretch and fit. This means that Lycra garments require low-heat washing and air drying, adding maintenance considerations.

Limited breathability: Lycra is often blended with other fibers, but in high concentrations, it may limit breathability. This can lead to discomfort during prolonged wear, especially in hot conditions. High-Lycra content garments may trap heat and moisture, making them unsuitable for all-day wear in warmer climates.

Cost: Lycra is generally more expensive than natural fibers and some other synthetic fabrics due to its unique properties and the complex production process. 

Lost stretch recovery over time: Although Lycra is known for its elasticity, prolonged and intensive use can lead to a gradual loss of recovery. Over time, Lycra garments may lose their original stretch, especially with frequent use and washing.

 

How Is Lycra Fabric Made?

Lycra fabric is made primarily through the solution dry spinning process, a multi-step manufacturing technique used for about 95% of Lycra production worldwide.

1. Prepolymer Production
2. Chain Extension Reaction
3. Dilution:
4. Extrusion
5. Heating
6. Twisting
7. Finishing
8. Weaving

Each step in this process is carefully controlled to produce Lycra’s distinctive properties: extreme elasticity, durability, and resilience, making it perfect for form-fitting and high-performance clothing.

 

Where is Lycra Fabric produced?

Lycra fabric, trademarked by DuPont, is produced worldwide, with significant manufacturing locations in countries such as the United States, China, India, Pakistan, and Brazil. 

While initially manufactured in the United States, production has shifted eastward over recent decades, with China becoming the largest exporter of Lycra and similar spandex products. China’s robust manufacturing infrastructure has made it a global hub for Lycra production, meeting the growing demand for stretchable, durable textiles in activewear, swimwear, and everyday apparel.

 

How does Lycra compare to other stretchable sports fabrics?

Lycra fabric stands out among other stretchable sports fabrics due to its superior elasticity, able to stretch up to eight times its original length while retaining shape.

This makes it ideal for sportswear that requires a high degree of flexibility, such as yoga pants, leggings, and cycling shorts. Unlike natural fibers that lose shape over time, Lycra’s synthetic structure offers resilience and durability, even with repeated washing and wear.

When compared to other stretch fabrics like polyester blends, Coolmax, and elastane fabrics like Drirelease or Repreve, Lycra offers enhanced breathability and moisture-wicking properties, making it comfortable for intense activities.

While polyester blends may provide a lower-cost alternative, they typically lack Lycra’s level of stretch and shape retention. Coolmax and Drirelease, on the other hand, focus more on moisture-wicking rather than stretch, so they’re often combined with Lycra for added flexibility.

Lycra also performs better in swimwear compared to some other stretch fabrics, as it is resistant to chlorine and UV rays, helping swimsuits retain elasticity and color over time. In comparison, Repreve is often used with Lycra in eco-friendly activewear but may lack Lycra’s elasticity when used alone. Overall, Lycra’s unique combination of stretch, durability, and comfort makes it a preferred choice for high-performance and active sportswear.

Feature	Lycra	Polyester Blends	Coolmax	Drirelease	Repreve
Stretchability	High (up to 8x original length)	Moderate	Low to moderate	Moderate	Moderate
Shape Retention	Excellent	Fair to Good	Fair	Fair	Good
Moisture-Wicking	High	Moderate	High	High	Moderate
Breathability	High	Fair to Good	High	High	Moderate
UV/Chlorine Resistance	High	Moderate	Low	Low	Moderate
Sustainability	Low	Varies	Low	Low	High (made from recycled materials)
Common Uses	Sportswear, Swimwear, Shapewear	Casual and Activewear	Activewear, Underwear	Activewear, Everyday Wear	Eco-friendly Activewear, Sportswear

 

How much does Lycra fabric cost?

The cost of Lycra fabric can vary widely depending on factors like quality, blend, and supplier. Generally, Lycra fabric prices range from $10 to $30 per yard, with higher-quality options or specialty blends, such as those used in high-performance sportswear, costing more.

 

Where are Lycra fabrics used?

Lycra fabric is known for its versatility and is used in a variety of applications across fashion, sportswear, and even specialized industries. Here’s how Lycra is utilized:

Form-Fitting Garments: Lycra is a popular choice in form-fitting clothing like underwear and socks. It’s often blended with other fibers to provide a snug, comfortable fit that molds to the body without causing discomfort.

Sportswear: Lycra is widely used in activewear and sportswear, such as leggings, cycling shorts, and yoga pants. Its elasticity allows for a full range of motion, which is essential for physical activities. Lycra is also breathable and moisture-wicking, keeping athletes cool and dry during workouts.

Swimwear: Lycra is resistant to UV rays and chlorine, making it perfect for swimwear. It helps swimsuits maintain color, elasticity, and a sleek fit even after extended exposure to sun and water.

Casual and everyday apparel: Lycra is also used in everyday clothing like jeans, T-shirts, and dresses. When blended with cotton or polyester, Lycra adds a slight stretch that improves comfort and fit, making it ideal for those who need flexibility.

 

What different types of Lycra fabric are there?

Standard Lycra:

This is the basic form of Lycra, known for its exceptional stretch and recovery properties.

Lycra Xtra Life:

Specifically designed for swimwear, Lycra Xtra Life provides additional resistance to chlorine, UV rays, and sunscreen lotions.

Lycra Sport:

Engineered for high-performance sportswear, Lycra Sport fabric offers excellent stretch, recovery, and muscle support. It’s designed to enhance comfort and durability in activewear, such as leggings, yoga pants, and compression garments.

Lycra Beauty:

This type of Lycra is crafted for shapewear and intimates, offering gentle compression and contouring while maintaining comfort. Lycra Beauty fabric is soft, smooth, and lightweight, making it perfect for lingerie, body-shaping garments.

Lycra T400:

Known for its dual-core yarn technology, Lycra T400 is highly resistant to wrinkling, sagging, and bagging. This type of Lycra is frequently used in denim and woven fabrics.

Lycra Soft Comfort:

This fabric is lightweight and breathable, designed for garments where comfort is paramount such as items like tops and sleepwear.

 

Align Textile: Your customized lycra fabric supplier

Align Textile offers customized Lycra fabric designs tailored to meet specific performance, comfort, and aesthetic needs, ensuring that each fabric blend maximizes the flexibility, durability, and functionality required for a variety of applications in activewear and fashion.

Below are examples of Lycra fabrics designed and manufactured by Align Textile:

Fabric	Main features	Composition
ACTOP18062	Athleisure Water Resistance Moisture Vapor WR/ 130*130 75D+40DOP* 150D+40DOP	90% Polyester,  10% Spandex
ACTOP23116	Athleisure Water Resistance Moisture Vapor Moisture Wicking/ 126*120 75D+OP* 75D+OP+150D	89% Polyester,  11% Spandex
AT19-A008	Athleisure Evaporation Cooling Moisture Wicking UV Resistance CoolmaxLycra Hybrid Moisture Wicking	67% Coolmax,  18% Polyester, 15% Lycra
AT19-A010	Athleisure Evaporation Cooling Moisture Wicking UV Resistance CoolmaxLycra Hybrid 4 Way Stretch Subtle Texture Effect Moisture Wicking	49% Coolmax,  46% Polyester,  5% Lycra

 

Align Textile is a leader in sustainable textile manufacturing, with over 20 years of experience in creating customized and eco-friendly fabrics. Known for its commitment to high quality and environmental responsibility, Align Textile operates an advanced R&D center and production facilities in Taiwan, offering more than 1,000 fabric options. Meeting international standards like AATCC, Align ensures products are crafted to meet diverse client needs.

Get in touch with Align Textile today and design your customized Lycra fabric!