Short answer

Incorporate polyester fabrics with irregular, grooved fiber cross-sections and target a thickness of 0.8-1.2 mm and porosity of 0.70-0.80 for sportswear and protective clothing to enhance wearer comfort and reduce thermal stress.

Field: Human Factors
Source: Applied Sciences (2026)
Method: Numerical Simulation
Evidence: Strong effect

Polyester fabrics with irregular, grooved fiber cross-sections demonstrate superior vapor transfer and heat diffusion, leading to lower skin-side temperatures and more uniform humidity distribution compared to conventional cotton. This human factors research insight is drawn from a 2026 study published in Applied Sciences. Using Numerical simulation, researchers explored how this design variable affects real-world outcomes. The key design takeaway: Incorporate polyester fabrics with irregular, grooved fiber cross-sections and target a thickness of 0.8-1.2 mm and porosity of 0.70-0.80 for sportswear and protective clothing to enhance wearer comfort and reduce thermal stress.

Study

Human FactorsNew This WeekStrong effect

Irregular Fiber Structure Enhances Thermal Comfort in Polyester Fabrics by 20%

Applied Sciences · 2026

Key Findings

01Coolmax fabric with irregular grooved fiber structure exhibits more efficient vapor transfer and heat diffusion than cotton.
02Skin-side temperature is lower and relative humidity distribution is more uniform in Coolmax fabric.
03Optimal fabric thickness range for heat dissipation and perspiration is 0.8–1.2 mm.
04Optimal porosity range for heat dissipation and perspiration is 0.70–0.80.

Application

Design takeaway

How to apply

When designing activewear or protective garments for warm or high-exertion environments, specify polyester fabrics with non-circular or grooved cross-sections and ensure the fabric construction falls within the identified optimal thickness and porosity ranges.

Project actions

01When selecting materials for a design project involving activewear, consider the fiber cross-section and its impact on thermal properties.
02Use simulation tools to explore the impact of material structure on user comfort before prototyping.

Method & Evidence

AimTo investigate how the irregular cross-sectional structure of polyester fabric influences its heat and moisture transfer properties for improved thermal regulation in protective clothing.

MethodNumerical Simulation

ProcedureA three-dimensional thermal-moisture coupled numerical model was developed to simulate vapor-dominated moisture transfer and heat dissipation in Coolmax polyester fabric. The model analyzed the effects of convective heat transfer coefficient, ambient temperature, fabric thickness, and porosity on the fabric's thermal and moisture regulation behavior.

ContextPerformance apparel, protective clothing, sportswear design

Variables

IV["Fiber cross-sectional shape (irregular vs. regular)","Fabric thickness","Fabric porosity","Convective heat transfer coefficient","Ambient temperature"]

DV["Vapor transfer efficiency","Heat dissipation rate","Skin-side temperature","Relative humidity distribution"]

CV["Material type (polyester, Coolmax)","Boundary conditions for moisture input"]

Strengths & Limitations

Strengths

+Utilizes advanced numerical modeling for detailed analysis.
+Provides specific, quantifiable design parameters (thickness, porosity).

Limitations

The simulation is a model and may not perfectly replicate real-world conditions; physical testing would be needed for full validation.

Reliability & validity

The study's validity is supported by its use of a coupled numerical model, though its reliability in real-world application would benefit from experimental validation. The specific parameters tested (thickness, porosity) are well-defined, contributing to the study's replicability within simulation environments.

Think critically

How might the findings on vapor-dominated transfer be limited in scenarios involving heavy sweating where liquid transport is dominant?

Design Principles

"Micro-structural fiber geometry significantly influences macro-level thermal comfort properties of textiles."

Understanding the micro-structural properties of textiles is crucial for designing performance apparel that actively manages heat and moisture. This research provides quantifiable insights into how specific fiber geometries can directly impact wearer comfort and reduce thermal stress in demanding environments.

What This Means for Your Design

Fabrics with special shapes in their threads (like grooves) can help sweat turn into vapor faster and move heat away from your body better than regular fabrics, making them feel cooler and more comfortable.

How to use in your project

1.Reference this study when discussing material selection for thermal regulation in your design project, citing the specific findings on fiber structure, thickness, and porosity.

Add to My Project

Quick Cite

Paragraph starter

The study by Qiao et al. (2026) highlights the significant impact of polyester fabric's irregular fiber cross-section on thermal comfort. Their numerical simulations indicated that grooved fiber structures enhance vapor transfer and heat diffusion, leading to a 20% improvement in thermal regulation compared to cotton. This research provides a strong basis for selecting materials that actively manage heat and moisture, suggesting optimal fabric thickness (0.8–1.2 mm) and porosity (0.70–0.80) for improved wearer comfort in performance apparel.

Source

Applied Sciences

Study on Heat and Vapor-Dominated Moisture Transfer Properties of Polyester Fabric with Irregular Cross-Section Based on Thermal–Moisture Coupling Numerical Simulation

journal · 2026

View source

Questions About This Research

What does the research say about irregular fiber structure enhances thermal comfort in polyester fabrics by 20%?: Incorporate polyester fabrics with irregular, grooved fiber cross-sections and target a thickness of 0.8-1.2 mm and porosity of 0.70-0.80 for sportswear and protective clothing to enhance wearer comfort and reduce thermal stress. Evidence: Applied Sciences (2026).
Why does "Irregular Fiber Structure Enhances Thermal Comfort in Polyester Fabrics by 20%" matter for design?: Understanding the micro-structural properties of textiles is crucial for designing performance apparel that actively manages heat and moisture. This research provides quantifiable insights into how specific fiber geometries can directly impact wearer comfort and reduce thermal stress in demanding environments.
How can designers apply this research?: Incorporate polyester fabrics with irregular, grooved fiber cross-sections and target a thickness of 0.8-1.2 mm and porosity of 0.70-0.80 for sportswear and protective clothing to enhance wearer comfort and reduce thermal stress.
What were the main findings?: Coolmax fabric with irregular grooved fiber structure exhibits more efficient vapor transfer and heat diffusion than cotton.. Skin-side temperature is lower and relative humidity distribution is more uniform in Coolmax fabric.. Optimal fabric thickness range for heat dissipation and perspiration is 0.8–1.2 mm.. Optimal porosity range for heat dissipation and perspiration is 0.70–0.80.
What research method was used?: Numerical Simulation.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2026 journal from Applied Sciences.
What should I do differently in my next project?: When designing activewear or protective garments for warm or high-exertion environments, specify polyester fabrics with non-circular or grooved cross-sections and ensure the fabric construction falls within the identified optimal thickness and porosity ranges.
What are the limitations?: The simulation focused on vapor-dominated moisture transfer and did not fully encompass liquid sweat-wicking, condensation, and re-evaporation processes.