Cloth nappy fabrics: an overview
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There is no doubt that cloth nappies are a more sustainable and eco-friendly choice compared to disposable nappies. Many parents motivated to use cloth for these reasons are also eager to know what cloth nappies are made of — not just from an environmental perspective, but also for peace of mind about what sits against their baby’s skin.
The explosion of nappies available on the market has been a huge positive in terms of affordability and access. Some parents may be happy knowing that whatever they choose, they are reducing landfill and saving money vs disposables. Others may want to prioritise organic cotton cloth nappies or bamboo/hemp options, which may sway which styles and brands they prefer.
Whichever end of the spectrum you fall, we hope this article demystifies the different types of cloth nappy fabrics.
What are cloth nappies made of?
The boom of nappies available on the market has been a huge plus in terms of making them more affordable and accessible. Some parents may be pleased knowing that regardless of which type of nappies they choose, they are helping to significantly reduce landfill waste while saving a fair bit of money on disposables.
Other parents might be motivated by a desire to use organic fibres as much as possible, which could influence their choice of styles and brands. For example, fitted nappies, AIOs, and AI2s often incorporate bamboo or hemp in the absorbent layers, and some cloth nappy brands have their materials organically certified.
Whichever side of the spectrum you’re on, we hope this article helps clear up some of the questions you might have about the materials that make up the various parts of cloth nappies.
What are the different parts of a cloth nappy?
While nappy styles vary, they generally consist of two main parts:
- waterproof covers and
- absorbent inserts.
Additionally, a ‘wicking’ or stay-dry layer is often used against the baby’s skin to draw moisture into the absorbent inserts and help the baby feel drier. Each part is made from different types of fabric to perform these complementary functions. We have grouped the fabrics into these three categories, but if you want to learn more about a specific material, click on it in the list below to go directly to it.
Nappy Covers: Waterproof and water-resistant fabrics:
• PUL (Polyurethane Laminate)
• TPU (Thermoplastic Polyurethane)
• Wool
• Fleece
• Softshell
Inserts: Absorbent layers
• Cotton
• Bamboo
• Hemp
• Microfibre
• Zorb
Stay-Dry Fabrics
• Brushed / suede cloth
• Microfleece
• Athletic Jersey
Each material plays a role in absorbency, breathability and comfort. If you need a quick reminder about the different types of cloth nappies, check out this article.
Nappy Covers: Waterproof and water-resistant fabrics
Cloth nappies feature a waterproof outer layer that keeps moisture inside the nappy and prevents leaks. This outer shell can be sewn into the nappy, as seen with all-in-one or pocket styles, or it can be a separate cover worn over a fully absorbent nappy, such as fitted nappies, flats, and prefolds. Here are some fabrics commonly used for waterproof covers.
PUL (Polyurethane Laminate)
PUL is one of the most common fabrics used in cloth nappy covers. It is a fabric with a thin polyurethane layer (TPU – see next section) bonded to it either through a chemical or high-heat industrial (thermal) process. It is more breathable compared to PVC and other plastic covers, comfortable to wear, and durable.
However, PUL fabric is not biodegradable. PUL can be washed and dried at moderate to high heat settings. It can also be bleached without fading or damage, which is a major advantage during sanitising wash cycles. Additionally, it can be easily wiped clean if not heavily soiled, making it a popular choice for AI2s and standalone covers, as they can be reused with fresh inserts. One of the main risks to PUL fabric is that it can be abrasive. Extremely high heat can damage it over time, potentially causing the waterproof layer to pull away from the lining. This process, known as delamination, can typically be prevented by following the manufacturer’s washing and care instructions.
Main Features: Durable, wipe-clean, bleach-safe. A common choice in AI2 shells and covers.
TPU (Thermoplastic Polyurethane)
Rather than being a type of fabric, TPU is actually a type of plastic film applied to PUL to improve its water resistance. TPU is laminated onto the PUL using one of two methods: either with chemical solvents during the bonding process or through high heat and pressure in a thermal bonding process. The latter method was developed in 2010 and is now the most commonly-used. This is because the thermal bonding process involves fewer chemicals in production, making the resulting PUL product more environmentally friendly, as well as soft, flexible, and durable – all very important qualities in a nappy cover!
Main Feature: Uses fewer chemicals in lamination, seen as a lower-impact alternative to PUL.
Wool
Wool makes a highly effective and attractive nappy cover, and when lanolised, it is the only natural fabric that provides excellent water resistance. Wool covers are effective at preventing leaks. As natural fibres, they are breathable and work by absorbing moisture that the nappy doesn’t.
A significant advantage of wool covers is that they don’t need washing after every use (unless they are obviously soiled!). Instead, you can simply leave them out to air dry.
Lanolinizing wool covers will enhance their water resistance while neutralising any odours. This process involves dissolving some lanolin in hot water and soaking the covers. You do not need to lanolise them every time you wash – once a month should be enough.
These factors make wool covers a perfect option for nights. However, they may not be the most practical choice for everyday use, as they can be bulkier and more expensive.
Main Features: Natural, breathable, lanolised for water resistance. Popular for overnight cloth nappy covers.
Fleece
Fleece is very breathable and water-resistant, making it popular in warm climates or during summer. It will repel water back to the nappy, keeping the outside dry. Fleece can sometimes experience compression leaks when your child remains in one position for a long time with a wet nappy, and moisture can wick to the outside. However, the advantage is that it can be washed with other nappies and requires minimal care.
Main Features: Lightweight, breathable, suitable for summer nappies.
Softshell
This term covers a range of fleeces typically used for outdoor clothing. Softshell is denser than polar fleece but provides better moisture protection. Some softshell fabrics include a breathable polyurethane layer inside that makes them waterproof. The levels of water resistance and breathability differ between manufacturers.
Main Features: Lightweight, breathable, suitable for summer nappies.
Inserts: Absorbent Layers
These are the types of fabrics that hold wee and absorb moisture in a nappy – essentially, the workhorse layers! The commonly used fabrics for absorbent layers include:
Cotton
Cotton is one of the most commonly used and easily available plant-based fibres. It is reasonably durable and inexpensive. Although not as absorbent as bamboo, it still performs well, and terry-towelling cloth remains one of the original fabrics used in cloth nappies, including flats, prefolds, and booster layers.
However, not all cotton materials are the same. There can be some chemical, ethical, and environmental concerns with cotton, which is why we recommend choosing organic cotton where possible.
Certified organic cotton is an excellent choice for cloth nappies because it is highly absorbent and gentle, making it suitable for babies with sensitive skin. To ensure you choose non-GMO and environmentally friendly cotton, be sure to verify the brand’s organic certification.
Main Feature: Affordable and durable, used in prefolds and flats . Organic cotton is softer and more eco-friendly.
Bamboo
Bamboo is another excellent choice for cloth nappy inserts because it remains soft even after many washes and is very absorbent or ‘thirsty’. Bamboo can absorb up to 60 percent more than the same weight of cotton, which makes bamboo nappies more trim. Bamboo captures moisture from the fabric and absorbs it quickly. It often comes in the form of velour, terry, and fleece.
From an ecological point of view, bamboo can be planted quickly and needs little or no pesticides. The only drawback is that it takes the longest to dry.
Main Feature: Very absorbent, trim fit, stays soft after many washes. Common in all-in-two nappies and best reusable nappies.
Hemp
Hemp is another absorbent fabric that can hold a lot of moisture while maintaining a thin layer. However, it does not absorb liquid as quickly as microfiber or cotton. That’s why cloth nappies made from hemp often include cotton blends.
Similar to bamboo, hemp is a fairly sustainable choice that can be cultivated using minimal water and few or no chemicals. Once again, this depends on the organic certification of the manufacturer. Hemp fabric may need to be washed several times before achieving maximum absorbency because of natural oils remaining on the fabric even after processing.
Main Features: Thin, ultra-absorbent, sustainable crop. May need to be washed several times for maximum absorbency.
Microfibre
Microfibre is a synthetic fabric, usually made from polyester. It quickly absorbs moisture and can hold a significant amount of liquid. It also dries faster compared to natural fibres like hemp and bamboo.
The way microfibre works is that the liquid molecules tend to attach themselves to the fibres rather than being absorbed by the cells. Therefore, pairing microfibre with bamboo or hemp can be an ideal combination for heavy wetters, sleeping, and long car trips. You should avoid placing microfibre directly on a child’s skin, as it can dry out the skin and over-absorb natural oils. It is better used as an inner layer between bamboo, hemp, or cotton to improve absorbency.
Main Features: Fast-absorbing and quick-drying, but must be layered under stay-dry fabrics. Suitable for long car trips or heavy wetters.
Zorb
This fabric is a blend of natural and synthetic materials designed specifically. for use in cloth nappies. Although some commercial nappies were made with Zorb a few years ago, such as overnight fitted nappies, Zorb is now mostly used in DIY nappy inserts. The original Zorb fabric is an interlining non-woven material made from tangled cellulose fibres from organic cotton, bamboo viscose, and polyester. This fabric can absorb ten times its weight in wetness in less than two seconds, which is significantly faster than cotton, bamboo, or hemp blends.
Main Features: Blend fabric, extremely fast absorption. Often DIY or custom inserts.
Stay-Dry Fabrics
Stay-dry materials are typically used inside nappies to prevent your baby from feeling wet against the skin. These layers do not absorb moisture themselves; instead, their role is to draw or ‘wick’ moisture away into the more absorbent layers. They are usually made from synthetic blends such as polyester.
Commonly, a stay-dry layer is either sewn in or added as a separate layer on top of the absorbent inserts (against the baby’s skin) to keep your baby feeling dry. They can be especially helpful for children prone to rashes caused by moisture.
An effective stay-dry layer allows liquid to pass through while holding back solids. This makes it easier to remove and dispose of poo in the toilet during changing, and helps prevent soiling the other nappy layers, making them more straightforward to clean. They are a good (and more sustainable) alternative to the so-called ‘flushable’ liners, as they can be washed with the nappies instead of being single-use items that must be thrown away. Stay-dry layers may also be used to line the cover shell or pockets. Below are some standard stay-dry fabrics.
Brushed/ Suede cloth polyester
Brushed / suede cloth is a synthetic fabric similar to microfleece, but it is woven without a pile or nap (the fluffy, soft top) like microfleece. It usually has one smooth side and one brushed side. The soft, brushed side typically comes into contact with the skin.
Suede cloth is lighter and thinner than microfleece, so many parents in warmer climates prefer it because it doesn’t feel as warm. It is very easy to sew and is an economical stay-dry fabric. It is commonly used as a lining for pocket nappies to wick moisture into the pocket inserts while catching solids.
Microfleece
Microfleece offers a cosy, soft feel – just like a fleecy blanket. Like other stay-dry fabrics, this polyester material effectively repels moisture and stays dry against the skin. Not to be confused with microfibre (see above), which absorbs moisture and can irritate a baby’s skin, microfleece is gentle and suitable as a layer against the skin.
It is very popular both as a standalone liner and as a built-in surface layer for absorbent inserts. It is also commonly used to line covers or pocket nappies. Although microfleece may tend to pill over time with washing and use, it will not impact its performance.
Athletic Wicking Jersey
Athletic wicking jersey is a synthetic knit usually made of polyester or nylon. It provides a comfortable, cool feel and quickly wicks moisture away, making it an obvious choice for the stay-dry layer. This fabric is ideal for wearing in warmer climates as it feels cooler and is more lightweight compared with suede cloth and microfleece.
Cloth Nappy Fabrics Comparison Table
| Fabric Type | Function | Pros | Cons | Best Use |
|---|---|---|---|---|
| PUL (Polyurethane Laminate) | Waterproof cover | Durable, wipe-clean, bleach-safe, widely available | Not biodegradable; very high heat can cause delamination | Everyday covers, AI2 shells |
| TPU (Thermoplastic Polyurethane) | Waterproof cover | Fewer chemicals in lamination; often seen as lower-impact than PUL | Still synthetic; can be less durable than wool | Lower-impact synthetic cover option |
| Wool | Waterproof/repellent cover (when lanolised) | Natural & breathable; odour-resistant; great for nights | Bulkier; higher cost; needs occasional lanolising | Overnight, breathable covers |
| Fleece | Water-resistant cover | Very breathable; easy to wash; budget-friendly | Compression leaks possible; not fully waterproof | Summer use, warm climates |
| Softshell | Water-resistant cover | More durable than fleece; some have hidden PU layer | Breathability varies; not always fully waterproof | Active babies, cooler weather |
| Cotton | Absorbent insert | Affordable, durable, familiar; organic options available | Less absorbent than bamboo/hemp; check sourcing/organic cert | Flats, prefolds, boosters |
| Bamboo | Absorbent insert | Very absorbent (“thirsty”); soft; trims well | Slowest to dry | Newborns, heavy wetters, trim nappies |
| Hemp | Absorbent insert | Ultra-absorbent; thin; sustainable crop | Slower to absorb; needs a few prep washes; can feel stiff | Night nappies, heavy wetters (often blended with cotton) |
| Microfibre | Absorbent insert (synthetic) | Very fast absorbing; quick drying; holds lots of liquid | Must not touch skin (can dry it out); less durable long-term | Pocket inserts, daycare spares |
| Zorb | Absorbent insert (blend) | Extremely fast absorbency; high capacity | Mainly DIY; limited in commercial nappies | Custom inserts, night boosters |
| Suede Cloth | Stay-dry liner | Lightweight; affordable; effective wicking | Synthetic; less breathable than natural fibres | Pocket linings; separate stay-dry liners |
| Microfleece | Stay-dry liner | Soft, breathable, gentle on skin | May pill over time (doesn’t affect performance) | Lining for pockets & covers; separate liners |
| Athletic Wicking Jersey (AWJ) | Stay-dry liner | Lightweight, cool, very breathable; fast wicking | Synthetic; not absorbent itself | Summer nappies; stay-dry layer in warm climates |