Finding and Selecting Polypropylene for Washable Masks

16 Jun.,2025

 

Finding and Selecting Polypropylene for Washable Masks

In this post we discuss how we think about selecting spunbond nonwoven polypropylene (NWPP) fabrics for washable masks, where we have found spunbond NWPP, and why we’ve chosen Smart-Fab® Double-Thick for our next round of testing.

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Our Mission

Our mission is to share information with the public about the best emerging mask science to help keep our communities safer.  We share this information both here on the website and on our Facebook page @themakermask and one of our favorite groups, @nwpp4masks. Since February , the MakerMask Team has been reading journal articles, talking to textile experts, testing mask fabrics, and seeking out relevant data.  Based on this science, we have developed and shared open-source mask designs and information about mask fabrics such as spunbond NWPP.

Public Health Guidance on Polypropylene for Fabric Masks

For MakerMask, sharing the science has been the easy part. The challenge has been finding sources for high quality spunbond NWPP material that meet our criteria for community masks during this global public health crisis. For reusable masks, we are looking for a spunbond NWPP that is:
  • breathable
  • water resistant
  • durable/tear-resistant
  • washable
  • available by the yard/meter
  • easy for sewists to source

Selecting Spunbond NWPP Sources

Unfortunately, the ideal spunbond NWPP mask materials have been hard to come by during this global crisis. Because data on commercially available materials is scarce and inconsistent, we have not been able to recommend a specific spunbond NWPP to sewists and makers.

However, sewists can evaluate the basic quality of NWPP sources by looking at how the material was originally intended to be used and existing industry and/or regulatory standards for those uses.

In general, industry standards suggest a hierarchy in the quality and manufacture of NWPP. For example, materials used for medical, food-contact, and textiles applications are typically required to meet minimum standards, whereas industry standards for disposable crafting and utility materials are less clear. 

  • Medical NWPP: Medical-grade spunbond NWPP is being reserved for medical masks and is not generally available to sewists. The type of spunbond NWPP typically used in medical masks is lighter (~25 gsm) than the spunbond available to sewists (> 40 gsm) and is not designed to be washable or reusable.
  • Food Contact NWPP: Materials designed to be in contact with food may be a good choice (e.g., reusable grocery bags) if medical grade materials are not available. However, they are not commonly available in bulk (i.e., by the yard or on the roll/bolt) for consumers.
  • Clothing & Textiles NWPP: Spunbond NWPP is used in clothing, bedding, and other textiles. These materials are sometimes available by the yard, are frequently designed to be washable, and are designed to be safe for skin contact. 
  • Crafting NWPP: Crafting NWPP is designed for crafting and classroom use but is not generally designed for reuse. Industry standards for the quality and manufacturing processes of crafting materials are unclear. However, some crafting materials are washable and manufactured following the same standards as other textiles. Crafting NWPP is widely available.
  • Utility/Upholstery NWPP: Utility/Upholstery NWPP (e.g., cambric) is designed to be durable, but is not designed to be washed or worn. Industry standards for the quality and manufacturing processes are unclear. 
  • Landscaping/ Geotextiles: NWPP used in Agriculture, Pond Liners, Geotextiles is frequently constructed with coarser fibers and has issues with particle shedding. It is not designed to be skin contacting, and it is generally considered not suitable for use in masks.

Finding Spunbond NWPP Sources for Mask Testing

Most medical-grade NWPP is currently reserved for medical use and not available to sewists for community masks, and the materials that are available are not usually washable. NWPP from reusable grocery bags, which is designed to be in contact with food, has been our top choice since early and was the focus of earlier testing efforts. However, the NWPP used in grocery bags isn’t commonly available by the yard/meter, and taking the bags apart to turn them into masks can be labor intensive.

  • Upcycled Reusable Grocery Bags. Reusable NWPP grocery bags are designed to be washable, breathable, water resistant, and in contact with food (See “The Big Four” for more information). Mask fabrics constructed from three layers of upcycled NWPP have passed ASTM Level 2 fluid resistance and are breathability requirements. Avoid previously used/worn/soiled materials. Avoid materials that are highly embossed/decorated because they might not be breathable, and may not stand up well to re-use.

Since medical and food-contact safe NWPP options are not readily available to sewists by the yard, we have focused on investigating the spunbond NWPP used in clothing, textiles, crafting, and upholstery applications for our next round of testing. 

The table below summarizes common spunbond NWPP sourcing options.

Smart-Fab® Double-Thick is Our Choice for Testing

Based on feedback from sewists, conversations with manufacturers and distributors, ease of online purchase, a review of the literature, and informal testing/evaluation of spunbond NWPP materials, we have selected Smart-Fab® Opaque (Double-Thick) for further investigation and formal laboratory testing and have prioritized getting this material to the lab as early as we can in . (Thank you to all who have donated to make this possible!)

Smart-Fab® Opaque Double-Thick Rolls

The Smart-Fab® Opaque Double-Thick is a midweight (67 gsm; 2.0 oz/yd2) crafting NWPP frequently used as a background material for bulletin boards. According to the manufacturer, Smart-Fab® Opaque (Double-Thick) is made from 100% virgin polypropylene and has been manufactured with quality and cleanliness controls consistent with clothing & textiles industry standards. For example, Smart-Fab was tested and approved to be compatible with the Fire Flammability Act Standard (16 CFR, part ) per the Consumer Product Safety Commission directive (report on file). According to Smart-Fab’s FAQ “In practical terms, it means that Smart-Fab is safe for usage in all the applications mentioned on our website, including in close proximity to children (e.g. in classrooms, for Halloween costumes, etc).”

  • Washing: Feedback from sewists suggests that it is washable, which is confirmed by the FAQ on the manufacturers website.
  • Availability: Smart-Fab is widely available in the U.S., Canada, and Australia (in the U.S,. it is available by the roll through Amazon, Walmart, and some craft stores like Dick Blick, which sells 48 inch by 24 foot rolls for $19.78 US).
  • Testing: Recently published literature suggests that 3 layers of Smart-Fab® provide decent filtration in fabric masks (Long et al, ). Smart-Fab double-thick should pass the “light” test sewists are familiar with for cotton fabrics.
  • Water-Resistance: DIY testing suggests that it is water resistant, but not as water resistant as the upcycled NWPP bags evaluated. 
  • Note: The Smart-Fab website states that Smart-Fab is food contact safe; however, this only applies to the “Smart-Fab Dairy” materials, and not to the Smart-Fab crafting materials.

Other Spunbond NWPP Sources

Cambric NWPP (e.g., Pellon 915)

Cambric NWPP is typically a lightweight (50 gsm; 1.5 oz/yd2) utility/upholstery NWPP that is frequently black in color. It is commonly used as a dust cover, especially for use under mattresses and other furniture items. If using a 50 gsm cambric, consider including at least one extra NWPP layer. This material is significantly lighter weight than the Smart-Fab Double-Thick and has a lighter/softer hand. 

  • Washing: Directions from the supplier say cambric should be spot cleaned. However, feedback from sewists suggests that it can be washed and reused. In addition, the Denver Mask Task Force has verified that the Pellon Cambric 915 can withstand sterilization in their autoclaves.
  • Availability: Cambric (black in color) is commonly available with the same specifications from three distributors in the U.S.: Pellon Cambric 915; DreamCraft LLC Cambric/Upholstery; and Dritz (Prym) Cambric/Upholstery.
  • Water-Resistance: In DIY water resistance tests it performed similarly to Smart-Fab Double-thick.

Sailrite Pillow Protector NWPP

Sailrite Pillow Protector NWPP material is a lightweight (40 gsm;1.2 oz/yd2) textile/upholstery NWPP that is marketed for use as a reusable pillow covering material. If using Sailrite spunbond NWPP, consider using one or two extra layers of the NWPP.  If using this, or other lightweight NWPP materials, consider using 2 or 3 layers wherever 1 layer of a heavier NWPP is recommended.  

  • Washing: The material provider (Sailrite) suggests this material can be washed and reused up to 5 times.
  • Availability: Pillow-protector NWPP is available online from Sailrite
  • Testing: The manufacturers provide some ASTM testing information for it (ASTM D -09), though not information commonly used by mask makers.
  • Water-Resistance: DIY testing suggests that it isn’t as water resistant as some of the other spunbond NWPP materials.

Oly-Fun NWPP

Oly-Fun is a midweight ( 65 gsm;1.9 oz/yd2) crafting NWPP. Oly-Fun feels more plastic-y than Smart-Fab and is stiffer and harder to work with/sew.

  • Washing: Joann’s fabrics provides the following washing instructions for Oly-fun “Care: Machine wash on gentle cycle and air dry; an iron may be used, but do so carefully on a cool or low setting with a pressing cloth”, however the manufacturer says that it should be considered a disposable single use material.
  • Availability: Oly-Fun is commonly available by the yard through Amazon, Walmart, and Joann’s fabrics.
  • Testing: Published literature suggests Oly-Fun can be used as a barrier in masks (Lustig et al, ).  
  • Water Resistance: DIY testing suggests that it is more water resistant than the Smart-Fab

Sew-In NWPP Interfacing

Sew-In NWPP interfacing is a textiles/clothing NWPP that may be available in lightweight, midweight, and heavyweight options. We are still looking for consistent, reliable, and available sources of materials and feedback from sewists. Availability by the yard varies significantly by region, and within the US, most of the sew-in interfacing available is made from polyester and not polypropylene. If using lightweight NWPP interfacing considering adding one or two extra NWPP layers. For information about Pellon 915, see the section on black cambric utility/upholstery NWPP.

  • Washing: Sew-In NWPP Interfacing is generally considered washable.
  • Availability: We’re heard good things about 70 gsm spunbond NWPP sew-in interfacing available to sewists at local shops and chains in Canada (e.g., Fabricland), but have not been able to source it online and for U.S. audiences.
  • Testing: The WHO guidance on fabric masks, and Zhou et al, suggest interfacing may have a good balance of filtration and breathability. 
  • Caution:  If using interfacing, avoid fusing interfacing as the glues and adhesives may reduce the breathability of the fabric and have unknown inhalation risks.

Sterilization Wrap (Medical NWPP)

Although rarely available to sewists by the yard, some types of 100% NWPP sterilization wrap may be suitable for use in masks. If considering sourcing medical NWPP, avoid heavy duty sterilization wrap that is not sufficiently breathable and take care with materials that are not washable (SMS wrap). Avoid materials with surface treatments that improve water resistance, but reduce breathability and may introduce inhalation risks. It is important to note that most sterilization wrap is a combination of spunbond-meltblown-spunbond (SMS) NWPP, which may not be washable.

  • Washing: Not usually washable
  • Availability: Generally available for hospital use, but not usually commercially available to sewists and community members.
  • Testing: A couple of studies have looked into the breathability of sterilization wrap and found that heavy duty sterilization wrap (e.g., H600) has decent performance on filtration, but it isn’t sufficiently breathable [Grigg et al, ; Sousan et al, ].  They suggest lighter weight sterilization wrap (e.g., H100 or H300) might be a better choice.

For More Information About Polypropylene in Masks Check Out:

  • The MakerMask FAQ: Questions About Polypropylene
  • The Big Four: Criteria For Community Mask Materials
  • Mask Fabrics: Introduction to Fibers and Fabrics

Polypropylene Fabric with Its Property () - BCG

Do you know about polypropylene fabric? 

Polypropylene fabric is one of the most used fabrics in the fashion industry. Today we will let you know about polypropylene fabric and its properties in detail. 

What Is Polypropylene Fabric?

Polypropylene fabric is a generic word for any textile product made from thermoplastic polymer polypropylene. This form of plastic is non-polar and somewhat crystalline, and it belongs to the polyolefin family. Polypropylene is the world’s second-most-produced plastic, behind polyethylene, and it’s more typically employed in packaging, straws, and other consumer and industrial goods than in textile production. 

Background of Polypropylene Fabric

Phillips Petroleum, an American business, was the first to produce this form of plastic in . When chemists Robert Banks and J. Paul Hogan tried to make gasoline from propylene, they created polypropylene by mistake. While the experiment was a failure, it realized that this novel compound has the potential to replace polyethylene in a variety of applications.

However, it wasn’t until that the development of polypropylene into a mass-production-ready material. Giulio Natta, an Italian chemist, and a German colleague succeeded in synthesizing this material into an isotactic polymer in , and the Italian company Montecatini rapidly began producing it for commercial and consumer use.

Polypropylene was first marketed under the brand name “Moplen,” which is still a registered trademark of LyondellBasell today. However, polypropylene, or “polypro” for short, is a much more common name for this material.

Want more information on polypropylene liner fabric? Feel free to contact us.

As polypropylene became increasingly widely used in a variety of consumer and industrial uses, it eventually realized that it could also use as a textile. Polypropylene fabric is a nonwoven textile, created without the need for spinning or weaving. The fundamental advantage of polypropylene as a fabric is its ability to transport moisture; this textile cannot absorb moisture and instead allows moisture to pass completely through it. 

Polypropylene fabric is one of the lightest synthetic fibers in existence. It is incredibly resistant to most acids and alkalis, and it melts at relatively low temperatures. Molten polypro fabric can cause serious burns, and this issue also makes it impossible to wash this fabric at high temperatures.

How Is Polypropylene Fabric Made?

Polypro, like other polymers, we normally manufactured from chemicals generated from hydrocarbon fuels such as petroleum oil. To make the polymer polypropylene, the monomer propylene we extracted as gas from crude oil and then subjected to a process called chain-growth polymerization.

How Is Polypropylene Fabric Used?

We can use Polypropylene plastic in thousands of different applications. This nonwoven fabric’s moisture-transferring properties have made it a popular textile for cold weather. Sportswear uses Polypropylene fabric, but issues with this type of plastic have made newer versions more popular. 

Polypropylene is a versatile material that can utilize in a wide range of applications. The moisture-wicking characteristics of this nonwoven fabric have made it a popular choice for cold-weather clothing. However, difficulties with this type of plastic have made newer versions more popular.

Where Is Polypropylene Fabric Produced?

China is the world’s largest exporter of polypropylene products at the moment. This country’s companies have generated $5.9 billion worth of polypro plastics in , expected that this trend will continue for the foreseeable future.

Beautiful Connection group is one of the best clothing manufacturers in the USA who produce the best women’s clothes. They work with every type of fabric, for example, Rayon, Silk, velvet, Polypropylene, etc. 

Germany produces a substantial amount of this material; in , Germany produced around $2.5 billion in polypropylene, and Italy, France, Mexico, and Belgium are other big producers of this material. Polypro goods were worth $1.1 billion in the United States in .

Sinopec Group, situated in Beijing, and PetroChina Group, also based in Beijing, come in second and third, respectively, in this business. The top ten producers of this chemical account for 55% of total polypropylene production worldwide.

We and others use Polypropylene in the manufacture of garments all around the world. China is the world’s largest producer of completed polypro textiles, and this type of fabric they used in garments and other materials in India, Pakistan, Indonesia, and other nations.

How Much Does Polypropylene Fabric Cost?

Polypro is one of the most extensively produced types of plastic, hence it is relatively inexpensive in large quantities. To dominate the global plastics market, a big number of distinct major firms compete with one another, driving prices down.

Polypropylene fabric, on the other hand, is quite costly. The main reason for the price increase is a lack of demand. This type of fabric is more expensive for textile manufacturers than similar synthetic textiles, such as polyester, and these costs are high on to the end-user. 

However, it’s important to note that this price rise only applies to polypropylene fabric which we used in clothing. Various forms of polypropylene fabric that aren’t suitable for garments for selling at a low cost. These textiles are available in a wide range of colors and textures. 

What Different Types of Polypropylene Fabric Are There?

To change the properties of polypro while it is still liquid, a variety of additives we can apply. Furthermore, there are two primary forms of this plastic:

  • Polypropylene homopolymer: Polypro plastic is homopolymer when it is in its natural state, without any additions. This type of polypro plastic isn’t typically thought of as a decent fabric material.
  • Copolymer polypropylene: Copolymer polypropylene is the most common form of polypropylene fabric. Polypropylene is of two types: block copolymer polypropylene and random copolymer polypropylene. In the block form of this material, the co-monomer units places in regular square patterns, but in the random form, the co-monomer units arranged in more random patterns. Fabric applications we can made using either block or random polypropylene, but block polypropylene is more popular. 

How Does Polypropylene Fabric Impact the Environment?

The production and use of polypropylene have a decidedly negative impact on the environment. Polypro plastic derives from hydrocarbon fuels, which have limited resources. It takes hundreds of years for this substance to decompose, so it is not biodegradable.                

Polypropylene Fabric Certifications Available

Polypro fabric is suitable for ISO certification, offered by the International Organization for Standardization, depending on the creation of. This company may also provide ISO certification for polypropylene goods used in medical applications.

Furthermore, the ISO has a separate certification method for polypropylene. This standard, ISO -1:, examines the tensility, impact resistance, and melt mass-flow rate of polypropylene to ensure that it meets basic requirements. The American National Standards Institute (ANSI) or NSF International might be able to certify this sort of plastic.

So by now, we expect that you have known pretty much everything about polypropylene fabric from this article. Hopefully, it was a helpful article for you. 

Contact us to discuss your requirements of Polyester Liner Fabric. Our experienced sales team can help you identify the options that best suit your needs.