Cloth Nappy Info

Cloth nappy fabrics: an overview

There is no doubt that cloth nappies are a more sustainable and eco-friendly choice compared with disposable nappies. 

Many eco-conscious parents are keen to know what materials cloth nappies are made of.  This can be important both from an environmental perspective, as well as wanting to be mindful of what you are putting against your baby’s skin.

Cloth Nappy Fabrics Explained

What are cloth nappies made of?

The explosion of nappies available on the market has been a huge positive in terms of increasing affordability and access.  Some parents may be happy knowing that whatever type of nappies they buy, they are doing their part to greatly minimize landfill waste while saving a heap of money on disposables.

Others parents may be driven by a desire to use organic fibres as much as possible, which may sway which styles and brands they opt for. For example, fitted nappies, AIOs, and AI2s often use bamboo or hemp in the absorbent layers, and some cloth nappy brands have their materials organically certified.

Whichever end of the spectrum you fall, we hope this article demystifies some of the questions you may have about the materials that make up the various components of cloth nappies.

What are the different parts of a cloth nappy?

While nappy styles vary, in general, they are made up of two basic components: waterproof covers and absorbent inserts.

In addition, a ‘wicking’ or stay-dry layer is often used against the baby’s skin to draw moisture into the absorbent inserts and ensure the baby doesn’t feel as wet.

Each component is made of different types of fabric to perform these complementary functions. We have grouped the fabrics under these three categories, but if you’re wanting to read up on a specific material then click on it in the list below to jump straight to it.

If you need a refresher on the different types of cloth nappies while you’re at it, check out this article

Nappy Covers: Waterproof and water-resistant fabrics

Cloth nappies utilise a waterproofing outer layer which has the important job of keeping the moisture inside the nappy and preventing leaks. This outer shell can be sewn into nappies, as is the case with all-in-one or pocket styles. Or it can be a completely separate cover that can be worn over a fully absorbent nappy, such as with fitted nappies, flats, and prefolds. Here are some fabrics commonly used for the waterproof cover.

PUL (Polyurethane Laminate)

PUL is one of the most common fabrics utilized in cloth nappy covers. PUL is a fabric with a thin polyurethane layer (TPU – see next section) that is bonded to it in either a chemical or high-heat industrial (thermal) process. It is more breathable when compared to PVC and other plastic covers, comfortable to wear, and durable.

Nevertheless, PUL fabric is not biodegradable. PUL can be washed and dried in moderately high-heat settings. It can likewise be bleached without getting the color faded or damaged, which is a huge advantage if performing a sanitise wash cycle.  They can also be easily wiped clean if not heavily soiled, so are a popular choice for AI2s and standalone covers as they can be reused with fresh inserts.

One of the biggest threats to PUL fabric is that it can be abrasive. Very high heat can damage them over some time, posing a risk of the waterproof layer pulling apart from the lining. This process is called delamination, but it can usually be avoided by following the manufacturer’s instructions for washing and care.

TPU (Thermoplastic Polyurethane)

Rather than a type of fabric, TPU is in fact a type of plastic film applied to PUL to enhance its water-resistance. TPU is laminated to the PUL using one of two processes: using chemical solvents in the bonding process or using high heat and pressure as part of a thermal bonding process. The latter technique was developed in 2010 and is now the most commonly-used process. This is due to the fact that the thermal bonding process uses fewer chemicals in production and so not only does it create a PUL product that is more environmentally-friendly, but is also soft, flexible and durable – all very important qualities in a nappy cover!

Wool

Wool can make for a highly effective and beautiful nappy cover, and when lanolised is the only natural fabric that can provide excellent water resistance. Wool covers work well at protecting against leaks. Since they are natural fibers, they are breathable and work by absorbing moisture that has not been absorbed by the nappy itself.

A huge bonus of wool covers is that they do not require washing after each use (unless soiled obviously!). Instead, you can leave them out to air dry.

Lanolising wool covers will enhance their water resistance while neutralizing any odours. This process involves dissolving some lanolin in hot water and soaking the covers. You do not need to lanolise it every time you wash it – once a month should be sufficient.

These factors make wool covers a particularly great option for nights. However, they may not be the most practical choice for everyday use as they can be bulkier and more expensive.

Fleece

Fleece is very breathable and water resistant so it popular in a warm climate or during summer. It will repel water back to the nappy hence keeping outside dry. Fleece can be subject to compression leaks when your child is in one position for a long period of time with a wet nappy and the moisture can wick to the outside. But the advantage is that it can be washed with other nappies and does not need a lot of care.

Softshell

This term covers a diversity of fleeces traditionally made for outdoor clothing. Softshell is dense when compared to polar fleece, but offers better moisture protection. There are some softshell fabrics with a breathable polyurethane layer hidden inside which makes them waterproof. The water resistance and breathability properties vary between different makes.

Inserts: Absorbent Layers

These are the type of fabrics that hold the wee and absorb the moisture in a nappy – essentially, the workhorse layers! The commonly-used fabrics for absorbent layers include the following:

Cotton

Cotton is one of the most commonly used and easily available plant-based fibres. It is relatively durable and inexpensive. Although not as absorbent as bamboo, it still does a great job, and terry-toweling cloth is one of the original cloth nappy fabrics still used in flats, prefolds, and booster layers.

However, not all cotton materials are created equal. There can be some chemical, ethical and environmental considerations around cotton, which is why we recommend choosing organic cotton where possible.

Certified organic cotton is a great option for cloth nappies since it is very absorbent and gentle, making it a great option for babies with sensitive skin. To find non-GMO and ecologically responsible cotton, be sure to check the brand’s organic certification.

Bamboo

Bamboo is another excellent choice for cloth nappy inserts as it stays soft even after many washes and it is very absorbent or ‘thirsty’. Bamboo can be 60 percent more absorbent when compared to the same weight in cotton, and this makes bamboo nappies trimmer. Bamboo traps moisture into the fabric and absorbs it quickly as well. It often comes in form of velour, terry, and fleece.

From an ecological perspective, bamboo can be planted quickly and requires no or few pesticides. The only downside is that it takes the longest to dry.

Hemp

Hemp is another absorbent fabric that can hold a lot of moisture while offering a thin fit in terms of layers. That said, it does not quickly absorb liquid like microfiber or cotton can. That is the reason why cloth nappies made from hemp often incorporate cotton blends.

Similarly to bamboo, hemp is a fairly sustainable option that can be grown with small volumes of water and few or no chemicals. Again, this will depend on the organic certification of the manufacturer. Hemp fabric can require washing a few times before it reaches peak absorbency because of natural oils that have been left on the fabric even after it has been processed.

Microfibre

Microfibre is a synthetic fabric, usually polyester. It rapidly soaks up moisture and can hold a lot of liquid. It also dries quickly when compared to natural fibres such as hemp and bamboo.

The way microfibre works is the molecules of the liquid usually attach themselves to the fibres instead of being absorbed by the cells. Therefore, using microfibre with bamboo or hemp can be a perfect combination for heavy wetters, sleeping, and long car trips. You should not place microfibre directly on the child’s skin since it can dry out the skin and absorb natural oils too much, therefore it is better used as an inner layer between bamboo, hemp, or cotton to enhance absorbency.

Zorb

This fabric is a blend of natural and synthetic materials made specifically for use in cloth nappies. Although some commercial nappies were manufactured with Zorb a few years ago such as overnight fitted nappies, Zorb is now mostly found in DIY nappy inserts. The original Zorb fabric is an interlining non-woven material constructed from tangled cellulose fibers from organic cotton, bamboo viscose, and polyester. This fabric can absorb wetness ten times its weight in less than 2 seconds, which is much faster when compared to materials such as cotton, bamboo, or hemp blends.

Stay-Dry Fabrics

Stay-dry materials are usually used inside nappies so that your baby doesn’t feel wet against the skin. These layers do not absorb moisture themselves – rather their job is to draw or ‘wick’ it away into the more absorbent layers. They are generally manufactured 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 ensure your baby isn’t feeling damp. They may be useful for children prone to rashes because of the moisture.

An effective stay-dry layer will allow liquid to pass through while holding solid substances. This makes it easy to remove and dispose of poo in the toilet when changing the nappy, and helps avoid soiling the other nappy layers, making them easier to clean. They are a great (and more sustainable) alternative to the so-called ‘flushable’ liners as they can be washed with the nappies, rather than the flushable liners which are single-use items that must be disposed of in the bin.

Stay-dry layers may also be used to line the cover shell or pockets. Below are some common stay-dry fabrics:

Brushed/ Suede cloth polyester

Brushed / suede cloth is a synthetic fabric that works similarly to microfleece but is woven so that it does not have a pile or nap (the fluffy, soft top) like microfleece. It usually features one smooth side and one brushed side. The soft brushed side usually goes against the skin.

Suede cloth is lighter and thinner than microfleece, therefore many parents in warmer climates prefer it since it does not seem so warm. It is very easy to sew and it 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 has a comfortable, soft feel – just like a fleecy blanket. Similarly to other stay-dry fabrics, this polyester fabric effectively repels moisture and will maintain a dry feel against the skin. Not to be confused with microfibre (see above) which absorbs moisture meaning it can irritate when placed against the babies’ skin, microfleece is gentle and perfectly acceptable as a layer against the skin.

It is very popular either as a separate liner or built-in as a surface layer to the absorbent inserts and is often also used to line covers or pocket nappies. Although microfleece may tend to pill over time with washing and use, it will not affect its performance.

Athletic Wicking Jersey

Athletic wicking jersey is a synthetic knit usually comprised of polyester or nylon. It allows for a comfortable, cool feel and it quickly wicks the moisture away, making it an obvious choice for the stay-dry layer. This fabric is perfect for wearing during warmer climates as it feels cooler and is more lightweight compared with suede cloth and microfleece.