What Is ECONYL Fabric? Properties, How It’s Made, and Where It’s Used

Sustainable textiles are reshaping today’s apparel industry, especially as more brands in the USA move toward recycled and regenerated materials. According to the Ellen MacArthur Foundation, over 500,000 tons of plastic microfibers enter the ocean each year from washing synthetic clothing. This is a major reason the industry is shifting to circular materials like ECONYL®.

ECONYL is one of the leading regenerated nylon fabrics used by global swimwear, activewear, and luxury brands. It transforms waste into high-performance yarn while offering the same strength and feel as traditional nylon. Manufacturers like Seam Apparel support this transition by helping eco-focused brands develop durable, sustainable, and responsibly produced apparel.

What Is ECONYL® Fabric?

What is ECONYL fabric?
ECONYL is a 100% regenerated nylon developed by Aquafil, an Italian materials company known for advanced recycling technologies. Unlike typical recycled plastics that are simply melted and reshaped, ECONYL fabric is created through a chemical regeneration process that brings nylon waste back to its original purity.

It is made from:

• Abandoned fishing nets
• Ocean plastic waste
• Old carpets
• Industrial nylon scraps

This regenerated nylon fabric can be recycled again, making it one of the most circular textile materials available today.

Simple Definition Box

What Is ECONYL Made From?

ECONYL fabric is created from several waste streams that would otherwise pollute oceans or accumulate in landfills. These materials are collected globally through dedicated recovery programs, ensuring that harmful waste is redirected into a circular production system.
The main sources include:

1. Ghost Fishing Nets

Abandoned fishing nets are one of the biggest threats to marine life. These “ghost nets” float for years, trapping fish, turtles, and other species. ECONYL actively partners with ocean clean-up initiatives to recover these nets and convert them into new nylon, giving harmful waste a second life.

2. Industrial Nylon Waste

Manufacturing sites often generate nylon scraps, offcuts, and defective materials. Instead of being discarded, these industrial waste streams are collected and sorted. They serve as a consistent and high-quality feedstock for ECONYL’s regeneration process.

3. Old Carpets

Millions of carpets are thrown away every year, and many contain nylon 6 fibers. These carpets are dismantled, separated from backing materials, shredded, and processed so the nylon fibers can be completely regenerated.

4. Textile Scraps

Cutting room leftovers, fabric edge waste, and pre-consumer textile scraps also contribute to ECONYL material. These scraps would typically be burned or dumped, but through the regeneration pipeline, they become valuable input for new yarn.

Key Point

All these waste materials go through a chemical regeneration process, where they are broken down into clean monomers rather than simply melted. This advanced method ensures that ECONYL behaves exactly like virgin nylon in strength, performance, and durability — but with a much lower environmental impact.

Want to know more about fabrics? Here is our blog on: What Is Linen Fabric: Properties, How It’s Made, and Where It’s Used. Check it out!

How ECONYL Is Made (Step-by-Step Regeneration Process)

Many readers searching for how ECONYL is made want a simple but accurate explanation of its chemical regeneration.
Here is the full process:

1. Waste Collection

• Ocean waste, industrial scraps, and discarded materials are collected through global recovery programs.

2. Sorting and Cleaning

• Materials are sorted to separate nylon-based waste from other plastics or contaminants.
• Deep cleaning removes dirt, salts, and impurities.

3. Depolymerization

• This is the most important step.
• Nylon waste is broken down chemically into its original monomer form (caprolactam).
• This is not mechanical recycling—it is reverse engineering the polymer chains.

4. Repolymerization

• The purified monomers are rebuilt into new nylon polymer chains identical to virgin nylon.

5. Yarn Production

• The regenerated nylon polymer is melted, extruded, and spun into ECONYL yarn.

6. Fabric Formation

The yarn is:

• Knitted for stretch fabrics
• Woven for stronger, structured textiles

7. Dyeing & Finishing

The yarn or fabric is dyed, heat-set, and finished according to product needs such as compression, softness, or UV resistance.

This scientific but circular process shows why ECONYL is considered one of the leading ecofriendly synthetic fabric options in the world. Private label manufacturers like Seam Apparel work with regenerated textiles and understand how they behave during production.

Properties of ECONYL Fabric

ECONYL properties make it one of the strongest sustainable nylon alternatives available today, and these performance and environmental advantages are the main reasons it is replacing virgin nylon in many USA-based activewear, swimwear, and luxury collections. The fabric offers the same technical strength as traditional nylon but with a significantly lower environmental footprint.

Performance Properties

• High durability – ECONYL is built for long-term use. It can withstand intense movement, repeated stretching, and exposure to water, making it ideal for performance sportswear and premium swimwear.
• Excellent stretch & recovery – The yarn blends smoothly with elastane, creating fabrics with strong four-way stretch. This helps garments like leggings, sports bras, and swimsuits stay supportive without losing shape.
• Chlorine resistance – ECONYL outperforms standard nylon in chlorine-rich environments. Swimwear made from regenerated nylon fabric lasts longer, holds color better, and withstands regular pool use.
• UV resistance – The fabric maintains its color and strength even under strong sunlight. This makes it suitable for outdoor workouts, beachwear, and summer apparel.
• Soft and smooth feel – ECONYL fabrics are known for their comfort. They feel gentle on the skin and reduce irritation during workouts, swimming, or daily wear.
• Lightweight – The material is naturally light, which improves mobility and enhances comfort during high-movement activities like running, training, or swimming.
• Quick-drying – ECONYL dries faster than many synthetic materials. This makes it practical for swimwear, activewear, and travel clothing where moisture management is important.

Sustainability Properties

• Made entirely from waste – ECONYL converts abandoned nets, industrial scraps, and textile waste into new fabric, reducing reliance on petroleum.
• Produces fewer CO₂ emissions – The regeneration process uses less energy compared to producing virgin nylon, lowering the overall carbon footprint.
• Can be regenerated multiple times – Because ECONYL is chemically rebuilt, it can be recycled again without losing quality, supporting a long-term circular system.
• Reduces ocean pollution – By removing fishing nets and waste plastics from the ocean, ECONYL directly contributes to cleaner marine environments.
• Supports circular material systems – It moves the textile industry away from a linear “take–make–waste” model and toward a regenerative approach.
• Releases fewer microplastics – While no synthetic is fully microplastic-free, regenerated nylon fabric is engineered to shed less than traditional nylon, helping reduce water pollution during washing.

Comparison Table: Nylon vs ECONYL

Types of ECONYL Fabrics

ECONYL yarn can be engineered into many fabric structures, giving designers and product developers flexibility across swimwear, activewear, luxury apparel, and accessories. Each type offers unique performance, texture, and stretch levels, allowing brands to match the fabric to their exact product needs.

1. ECONYL Stretch Jersey

This is one of the most popular ECONYL fabric types. It is soft, smooth, and highly flexible, making it perfect for garments that need strong stretch and a comfortable skin feel. Stretch jersey is widely used in premium swimwear, yoga wear, and everyday activewear because it offers excellent recovery and holds its shape after repeated use.

2. ECONYL Ribbed

Ribbed ECONYL has a textured surface that adds visual depth and gentle compression. It feels supportive while still maintaining flexibility, making it ideal for swimsuits, sports tops, and stylish athleisure pieces. Many modern swimwear lines use ribbed structures to add a luxurious, on-trend finish.

3. ECONYL Mesh

This type is lightweight, breathable, and designed for airflow. ECONYL mesh works well in areas that need ventilation or lower weight, such as sports inserts, activewear panels, pockets, or linings. It is also used in performance wear, where moisture control and breathability are essential.

4. ECONYL Compression Fabric

Compression fabrics made with ECONYL are dense, strong, and supportive. They offer high stretch with controlled tension, making them suitable for leggings, cycling shorts, shapewear, and performance-focused apparel. These fabrics help stabilize muscles and provide a sculpted, athletic fit.

5. ECONYL Woven Blends

Woven ECONYL materials are more structured and durable. They are commonly used in luxury bags, small accessories, lightweight outerwear, and high-end fashion items. Woven blends offer a clean, sleek finish with excellent strength and abrasion resistance.

Product performance depends heavily on the fabric structure, not just the fiber.
Different ECONYL fabric types behave differently when stretched, sewn, printed, or washed. Seam Apparel guides brands in selecting the right ECONYL structure for each product category, ensuring durability, comfort, and the desired aesthetic.

Where ECONYL Fabric Is Used

Today, ECONYL is widely used across multiple industries. Its recycled nylon fabric offers premium performance along with strong sustainability appeal.

Common Uses of ECONYL Fabric

• Swimwear (bikinis, one-pieces, chlorine-resistant suits)
• Activewear (leggings, sports bras, tanks)
• Performance outerwear
• Luxury fashion
• Footwear linings
• Eco-friendly underwear
• Bags, wallets & premium accessories
• Designer apparel (used by high-end brands)

USA-based sustainable swimwear and activewear labels often select ECONYL material because it meets both performance and ethical production goals. Manufacturers such as Seam Apparel assist brands that want to bring eco-focused collections to life.

Why Brands Choose ECONYL

ECONYL is becoming a top choice for brands that want luxury-level performance with meaningful sustainability benefits.

Key Advantages

• Reduces plastic waste from oceans and landfills
• Premium durability for high-activity apparel
• Looks and feels like luxury nylon
• Lower climate impact
• Strong consumer demand for sustainable products
• Suitable for high-end fashion, swimwear, and technical wear

Well-known global brands such as Prada, Adidas, and Stella McCartney rely on ECONYL material for their sustainable product lines.

Limitations of ECONYL

Although ECONYL is one of the strongest sustainable nylon alternatives, it has a few limitations that buyers should understand.

1. Higher Cost

Regeneration technology is expensive, so ECONYL costs more than standard nylon.

2. Limited Color Options

While improving each year, color availability is still less flexible than polyester.

3. Supplier-Specific Material

Aquafil is the main supplier. This means demand is high, and availability can vary.

4. MOQ Requirements

Some mills and manufacturers may require minimum order quantities.

Being transparent about these limitations builds trust with eco-conscious consumers and brands.

How to Choose ECONYL for Your Product

Choosing the right regenerated textiles requires a technical approach.
Here are the factors that product developers, designers, and sustainable brands should evaluate:

1. Fabric Weight (GSM)

• Lighter weights for swimwear
• Medium weights for leggings
• Heavy weights for compression or performance garments

2. Stretch and Recovery

Check the percentage of elastane and test four-way stretch if needed.

3. Intended Use

• Swimwear → chlorine-resistant ECONYL jersey
• Activewear → compression blends
• Luxury → woven ECONYL or textured knits

4. Certifications

Look for:

• Global Recycled Standard (GRS)
• OEKO-TEX Standard 100

5. Printed vs. Solid Fabrics

Sublimation printing works extremely well on ECONYL stretch materials.

6. Lining Options

Pair with soft, lightweight recycled linings.

7. Performance Testing

Test for:

• Pilling
• UV resistance
• Chlorine exposure
• Moisture management
• Colorfastness

Manufacturers with experience in technical textiles—such as Seam Apparel—can guide brands through material selection and testing.

Why Seam Apparel Recommends ECONYL for Sustainability-Focused Brands

Eco-driven brands across the USA rely on sustainable materials, and ECONYL is one of the most reliable choices for durability and environmental responsibility. Seam Apparel works closely with recycled and regenerated materials and provides:

• Support with sourcing ECONYL fabrics
• Low-MOQ options for new brands
• Technical expertise in sewing recycled and stretch fabrics
• Guidance for swimwear, activewear, and eco-friendly apparel development

Conclusion

ECONYL is one of the most advanced circular materials available today. By transforming waste into high-performance regenerated nylon fabric, it offers a real solution for brands that want to reduce their environmental impact without sacrificing quality.

From swimwear and activewear to luxury fashion, ECONYL material is shaping the future of sustainable textiles. With expert partners like Seam Apparel, USA-based brands can confidently create eco-friendly collections that meet modern performance and sustainability standards.

If you want to develop swimwear, activewear, or sustainable garments using ECONYL fabric. Contact Seam Apparel to help bring your ideas to life.