How Synthetic Fibers Came to Dominate the Upholstery & Drapery Industry

When you think of polyester, you might picture 1970s leisure suits or scratchy bargain-bin fabrics. But here’s a secret: polyester is the unsung hero of today’s upholstery & drapery world.

As a business who’s been in the home textile fabric industry since the Truman era, we’ve watched this underdog fiber evolve into a powerhouse—and it’s time to set the record straight.

From Apparel to Armchairs: How Polyester Took Over

In the 1970s, many of the textiles used in apparel and upholstery were produced domestically. The U.S. was home to numerous weaving mills, and fabrics were largely sourced from local manufacturers. At that time, the industry was tightly knit, with weavers specializing in different types of fabrics for furniture and drapery.

Additionally, early on, decorative upholstery and drapery fabrics were natural: cotton, wool, or silk. But as global trade expanded, manufacturers faced a challenge: how to deliver beauty, durability, and affordability. Enter synthetic fibers.

Polyester’s dominance started in apparel because - at the time – the majority of textiles were used for clothing. Economies of scale made it cheap to produce and the supply was abundant. Eventually, the upholstery and drapery industry caught up and realized that they could use synthetic fibers in furniture applications too.

However, early some synthetics had a bad rap. They felt stiff, looked shiny, and durability was not nearly as sound as it is today.

Then came the game-changers:

• Round and Tri-Lobal Filaments: Extruding round filaments would provide a dull, cotton like luster, whereas extruding tri lobal fibers with tiny ridges (picture a camshaft), mills could control its sheen. Silk looks could be achieved with tri lobal filaments.
• Blending Magic: Mixing polyester with natural fibers (e.g., linen or cotton) created fabrics that were soft, breathable, and stain-resistant.
• High-Tech Finishes: Treatments like Crypton® turned these new fabrics into a spill-defying fortress, while processes like Biancalani softened it to cloud-like comfort.

Why Designers (and Customers) Love Modern Polyester

Today’s polyester isn’t your grandma’s couch fabric. It’s a top choice for several reasons:

Today, we can even create 100% polyester pile velvets that look and feel like luxurious cotton and customers are shocked when we tell them it’s synthetic.

The Future of Fabric: Sustainability Meets Innovation

Critics have argued that synthetics aren’t eco-friendly, but the industry is evolving.

Recycled polyester from plastic bottles has gained traction, and efficient weaving technology reduces waste.

The key is balance between synthetic fabrics and ensuring that they have a natural appeal. Polyester and other synthetic fabrics let us create long-lasting upholstery for furniture and drapery fabric that doesn’t end up in landfills after two years.

Next time you shop for upholstery or drapery fabric, don’t overlook those containing synthetic fabrics. It’s proof that “synthetic” doesn’t mean “cheap”—it means smarter.

At Decorative Fabrics Direct, we’ve spent decades partnering with global mills to source the best-performing and most pleasing, stylish fabrics. Request a sample today, and feel the difference for yourself.