The swimwear industry is diving deeper than ever into textile innovation. With rising demand for high-performance, eco-friendly, and fashion-forward swimwear, the materials behind the garments are evolving rapidly. Whether you’re designing bikinis for retail, sourcing technical fabrics for water sports brands, or launching an eco-conscious capsule collection, understanding the nuances between nylon, polyester, and recycled materials is essential. Nylon offers stretch and softness, polyester excels in UV and chlorine resistance, and recycled fabrics like ECONYL® and rPET add sustainability without compromising performance. The latest innovations combine these strengths to meet both design and environmental demands in swimwear production.

Now imagine this: a startup swimwear brand looking to launch a bold neon-colored bikini set. The founders initially choose nylon for its silky feel and fit. But during wear tests, they find the suits fade in the sun and lose elasticity in chlorinated water. They then switch to a recycled nylon-spandex blend with UV resistance—instantly improving product reviews and longevity. This story isn’t rare. The right fabric can make or break your swimwear line.

So how do you choose the right material for your market, budget, and sustainability goals? Let’s break it down.

What Are the Key Differences Between Nylon and Polyester in Swimwear Fabric?

The key difference between nylon and polyester lies in elasticity, texture, and environmental resistance. Nylon is softer, stretchier, and better suited for form-fitting swimwear, while polyester is more resistant to UV rays, chlorine, and color fading. Nylon feels premium; polyester performs longer under harsh conditions. Nylon provides better stretch and comfort, while polyester offers higher resistance to UV, chlorine, and fading. The choice depends on whether fit or longevity is prioritized.

Head-to-Head Comparison by Performance Metrics

Which Should You Use When?

• For premium bikini sets or shapewear-style swimwear: Nylon or nylon-spandex blends are better due to fit and softness.
• For athletic, competitive, or long-lasting beachwear: Polyester blends withstand UV, salt, and chlorine better.
• For printed designs or high color vibrancy: Polyester performs better with sublimation and long-term colorfastness.

A U.S.-based water aerobics brand originally used 80/20 nylon-spandex for its swimwear line. After customer complaints of fading and elasticity loss, they transitioned to a 75/25 polyester-spandex blend. Return rates dropped by 35% and shelf life increased by 40%.

💡 Insider Tip: Ask your fabric supplier about chlorine-resistant treatments for nylon if softness is critical to your design, but durability still matters.

How Do Recycled Swimwear Fabrics Compare to Virgin Nylon and Polyester?

Recycled swimwear fabrics—like ECONYL® (regenerated nylon) and rPET (recycled polyester)—perform almost identically to virgin materials but come with a significantly lower environmental footprint. They’re being used increasingly by brands targeting Gen Z and eco-conscious markets. Recycled fabrics like ECONYL® and rPET match virgin nylon and polyester in performance but use post-consumer or industrial waste, reducing CO₂ emissions by up to 80%.

Recycled Fabric Innovations

1. ECONYL® – Regenerated Nylon

• Made from discarded fishing nets, fabric scraps, and ocean plastic
• Matches the tensile strength, stretch, and dyeing properties of Nylon 6
• Supported by brands like Adidas, Mara Hoffman, and Girlfriend Collective
• Reduces CO₂ emissions by \~80% compared to virgin nylon

2. Recycled Polyester (rPET)

• Made from plastic bottles and textile waste
• Slightly stiffer than virgin polyester
• Best used in board shorts, rash guards, or active swim tops
• Reduces energy use by 45% and water use by 20%

3. Cost and MOQ Considerations

4. Limitations

• Slightly higher cost than virgin equivalents
• Limited color options unless using larger volume dye lots
• Lead time may be longer due to yarn regeneration processes

5. Real-Life Use Case A European DTC swimwear brand switched to ECONYL® for all their high-waisted bikini bottoms. Their conversion rate on product pages jumped by 22% after adding “Made from Recycled Nylon” to the description, and their PR mentions increased 3x.

🧵 Sustainability Tip: Request a breakdown of the percentage of recycled content used. Some suppliers may market a blend as “recycled” even if only 30% of the yarn is post-consumer waste.

Which Fabric Offers the Best Stretch, Fit, and Shape Retention in Swimwear?

When it comes to stretch, fit, and shape retention, nylon-spandex blends outperform both polyester and recycled alternatives. Nylon offers a smoother, more elastic base, while spandex adds the rebound power that helps garments hug the body. Polyester-spandex blends are durable but less form-fitting, while recycled fabrics vary depending on blend composition. Nylon-spandex blends offer the best stretch and shape retention for swimwear, delivering a snug, flattering fit with excellent recovery even after multiple wears and washes.

What Makes Stretch Matter?

1. Stretch Capacity & Recovery Ratings

2. Why Recovery Is Key Recovery means the fabric bounces back to its original shape after stretching. Poor recovery leads to saggy bottoms, stretched-out straps, and unflattering fits over time—major red flags for consumers.

3. Spandex Ratios and Their Impact

• 80/20 blend: Maximum stretch and support
• 85/15 blend: Balance of comfort and compression
• 90/10 blend: Budget-friendly but lower recovery

4. Testing: The Snapback Index In a simulated wear-test study involving 30 swimwear samples over 20 wash-and-dry cycles:

• Nylon-spandex garments retained 91% of original elasticity
• Polyester-spandex blends dropped to 84%
• ECONYL®-spandex fabrics held 89%, with less visible pilling

💡 Fit Tip: For size-inclusive collections, use circular-knit nylon-spandex blends that stretch in four directions (4-way stretch) for better shaping across body types.

Are Nylon or Polyester More Resistant to Chlorine, Saltwater, and UV Exposure?

Polyester is more resistant to chlorine, saltwater, and UV rays than nylon. However, nylon can be treated for chlorine resistance and UV protection, making it viable for swimwear that prioritizes comfort and stretch over extreme durability. Polyester naturally withstands chlorine and UV exposure better than nylon, but treated nylon fabrics can reach comparable performance while offering a softer, more luxurious feel.

Environmental Exposure and Fabric Lifespan

1. Chlorine Resistance

• Polyester: High inherent resistance; color and fiber hold up well in chlorinated pools
• Nylon: Prone to yellowing, stiffness, and loss of elasticity unless chlorine-resistant treatments (e.g., Xtra Life Lycra®) are applied
• Recycled Options: ECONYL® shows improved resistance with advanced finishing

2. UV Resistance

3. Saltwater Durability

• Both polyester and nylon hold up well in saltwater
• Finishes like anti-salt coatings can extend lifespan by 20–30%
• Spandex content degrades faster in salt, so rinsing is essential

4. Wear Simulation Study: Chlorine & Sun Exposure After 40 hours of chlorine pool immersion + 20 hours of UV lamp exposure:

A Canadian brand specializing in swim training gear tested both nylon and polyester for uniforms. Polyester suits lasted twice as long but didn’t provide the same body-sculpting fit. The final design used a polyester exterior for durability and a nylon lining for comfort.

🧵 Fabric Strategy Tip: If your customers spend more time poolside than in the pool, prioritize feel over longevity. If they’re triathletes or water gym regulars, lean into polyester.

What Are the Environmental Impacts of Nylon, Polyester, and Recycled Materials?

The environmental impact of swimwear fabrics is significant—particularly for virgin nylon and polyester, both of which are derived from petrochemicals and require large amounts of energy and water. In contrast, recycled materials like ECONYL® and rPET drastically reduce emissions, waste, and water usage. Virgin nylon and polyester are petroleum-based and resource-intensive, while recycled options like ECONYL® and rPET reduce carbon emissions by up to 80%, offering more sustainable choices for eco-conscious swimwear brands.

Life Cycle Assessment (LCA) of Swimwear Fabrics

1. Virgin Nylon (Nylon 6 or 6,6)

• Derived from crude oil
• High CO₂ output (\~5.4 kg CO₂/kg of fabric)
• Non-biodegradable
• Requires chemical-intensive dyeing

2. Virgin Polyester (PET)

• Also petroleum-based
• Slightly lower emissions than nylon (\~4.3 kg CO₂/kg)
• Common in fast fashion and sportswear
• Difficult to biodegrade but easy to recycle

3. Recycled Nylon (ECONYL®, Q-NOVA®)

• Made from fishing nets, fabric scraps, carpets
• CO₂ emissions drop to \~1.8 kg CO₂/kg
• Closed-loop regeneration
• Same durability and stretch as virgin nylon

4. Recycled Polyester (rPET)

• Derived from post-consumer plastic bottles
• Emissions: \~2.0–2.5 kg CO₂/kg
• Reduces landfill plastic waste
• Best for digital print swimwear or casual swim lines

Environmental Impact by Fabric Type

5. Certifications That Matter

• GRS (Global Recycled Standard)
• OEKO-TEX Standard 100
• Bluesign® Approved
• Higg Index Scores

🌍 Sustainability Tip: Always ask your supplier for GRS certification and transparency on yarn content. Some “recycled” fabrics are actually blends with only 20–30% recycled content.

How Do Dyeing and Colorfastness Vary Across Nylon, Polyester, and Eco-Fabrics?

Dyeing and colorfastness play a critical role in the look, longevity, and branding appeal of swimwear. Nylon is easier to dye and achieves more vibrant, saturated hues, but it can fade faster under UV. Polyester, while harder to dye, holds color longer—especially with sublimation printing. Recycled fabrics vary depending on their base and treatments. Nylon dyes easily and vibrantly but fades faster; polyester is more UV-resistant and holds color better, while recycled fabrics perform similarly to their virgin counterparts depending on treatment and print method.

Dyeing Techniques and Performance Insights

1. Dye Affinity by Fabric Type

2. Sublimation vs. Acid Dyeing

Sublimation Printing:

• Only works on polyester (recycled or virgin)
• Produces photographic-quality prints
• High UV/colorfastness; no feel on fabric surface

Acid Dyeing:

• Used for nylon and nylon blends
• Allows for deep, saturated colors
• Fades faster under UV unless treated

3. Colorfastness Ratings (AATCC 16 test standard)

4. Real-World Insight A fashion swim brand in LA wanted neon greens and reds for a limited drop. Nylon performed best for vibrancy, but within 3 months, faded units prompted returns. They reformulated with UV-treated polyester, sacrificing some softness for durability—and saw complaints drop to near zero.

🎨 Color Tip: If color is a key part of your branding, combine nylon with UV-protective dye treatments or opt for sublimation-printed rPET for best visual longevity.

Which Swimwear Fabrics Are Most Preferred by High-End vs. Budget Brands?

High-end swimwear brands tend to favor nylon-spandex blends and recycled nylon (like ECONYL®) for their softness, stretch, and luxury appeal. In contrast, budget and mass-market brands often use polyester blends or rPET fabrics, which offer durability, lower costs, and vibrant print compatibility at scale. Luxury brands prioritize nylon and recycled nylon for comfort and brand storytelling, while budget brands prefer polyester or recycled polyester for cost-efficiency and print versatility.

How Brand Positioning Influences Fabric Choice

1. High-End/Luxury Swimwear Brands

• Common Fabrics: Nylon-spandex (80/20, 85/15), ECONYL®

Key Priorities:

• Silky hand-feel
• Superior stretch and body contour
• Sustainability messaging (e.g., “Made from ocean plastic”)

Brands Using These:

• Eres (Chanel) – Nylon with Lycra® Xtra Life
• Mara Hoffman – ECONYL®
• Zimmermann – Fine nylon blends

2. Budget/E-commerce/Private Label Brands

• Common Fabrics: Polyester-spandex (80/20), rPET

Key Priorities:

• High durability in chlorine and sun
• Bold printed designs using sublimation
• Low unit costs for large orders
• Brands Using These:
  • Shein, Target’s Xhilaration, Amazon labels

3. Fabric Cost Breakdown by Brand Tier

💡 Brand Strategy Tip: Even budget brands can integrate a recycled swimwear line with minimal cost increases (\~\$0.40–\$0.60/unit) while adding ESG appeal.

Do Minimum Order Quantities and Lead Times Differ for Nylon, Polyester, and Recycled Fabrics?

Yes. Polyester fabrics generally offer the lowest MOQs and fastest lead times, while recycled fabrics require higher MOQs and longer production cycles due to yarn processing. Nylon strikes a balance—quick to produce, but customization and dyeing may increase turnaround. Polyester has the lowest MOQs and fastest delivery; recycled fabrics like ECONYL® require higher volumes and longer lead times, while nylon sits in the middle.

Sourcing Logistics by Fabric Type

1. Typical MOQ and Lead Time Chart

2. Factors That Influence Lead Time

• Custom Color Matching: Add 5–7 days for lab dips
• Eco-Certification Requests: Some labs need 7–10 extra days
• Holiday Schedules: Always buffer 1–2 weeks around Chinese New Year or major sourcing regions’ holidays

3. Logistics Best Practices

• Consolidate multiple SKUs in one dye lot to lower MOQ
• Use in-stock yarn shades for quick replenishment
• Opt for sample yardage first if testing market response

🎯 Sourcing Tip: For startups or new drops, ask your supplier about shared bulk dyeing—some manufacturers can group small orders into a larger lot to help you reach MOQ thresholds.

Ready to Choose the Best Swimwear Fabric for Your Brand?

The right swimwear fabric can define not just your product’s fit and comfort—but your brand’s identity, sustainability footprint, and ability to scale. Whether you prioritize softness, color vibrancy, chlorine resistance, or eco-innovation, your fabric choice shapes how your product is experienced, reviewed, and remembered.

To summarize:

• Nylon wins on stretch, softness, and premium feel
• Polyester dominates for durability, color retention, and printability
• Recycled fabrics like ECONYL® and rPET deliver on performance and sustainability

Choosing the right one is about knowing your customer, your margins, and your values.

Partner with SzoneierFabrics for Custom Swimwear Fabric Solutions

At SzoneierFabrics, we help B2B clients across the globe create swimwear that stands out. From custom prints to Pantone-matched colors and recycled blends, our team provides end-to-end development and manufacturing support for your brand.

🌟 What We Offer:

• Custom fabric R\&D (nylon, polyester, ECONYL®, rPET)
• 100% quality guarantee
• Low MOQ starting from 200 yards
• Fast sampling (3–7 days)
• Free samples and lab dips
• Pantone color matching & eco-certification support
• Short lead times for global shipping

📩 Contact Us Today 📧 Email: Info@szoneierfabrics.com 🌐 Website: https://szoneierfabrics.com 📞 Phone: (+86) 13823134897

Let us help you build your next swimwear collection with materials that fit better, last longer, and perform sustainably.