Customers say our leggings lose stretch after tumble drying. Fabric fault or care issue?

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Flat illustration of stretch arrows, a knit fabric swatch and a thread spool

Customers say our leggings lose stretch after tumble drying. Fabric fault or care issue?

Heat can affect elastane, and so can the fabric construction. Test growth and recovery after the drying your label allows, then decide whether to change the fabric, the label or both.

Activewear & CompressionKnitwear Talk3 min readKnitwear Base Editorial Team
Flat illustration of stretch arrows, a knit fabric swatch and a thread spool
Buyer question

Our nylon-elastane leggings get reviews saying they go baggy at the knees and waistband after a few tumble dries. The label says "tumble dry low". Is the fabric at fault, or should we just change the care label?

Main answer
Knitwear Base Editorial Team
Main answer

It may be both, and a short test programme will tell you which. Bagging at the knees is usually about fabric growth, the stretch that does not recover. Bagging at the waist can also involve the waistband elastic. Heat during drying is one factor that can reduce recovery, but construction, elastane content and finishing also matter. Test before you decide.

Measure growth and recovery, before and after

For the body fabric, ASTM D2594 covers stretch properties of knitted fabrics having low power, including fabric growth. For the waistband elastic, ASTM D4964 measures tension and elongation of elastic fabrics on a constant-rate-of-extension tester. Run both on new material, then on material that has been through a named laundering and drying procedure. ISO 6330 includes defined drying procedures, among them tumble drying. Compare new with dried results.

Read the result both ways

If recovery stays acceptable after the drying your label allows, the complaints may reflect hotter drying at home than the label states. In that case clearer care advice is a reasonable response. If recovery drops noticeably even under the labelled drying, the label is promising too much for this fabric. Either change the care instruction to a gentler method the fabric does tolerate, or ask the mill about a construction or elastane that holds up.

Keep the label within the evidence

ISO 3758 symbols indicate the most severe treatment that does not cause irreversible damage, and US rules expect care instructions to have a reasonable basis. A "tumble dry low" symbol or instruction should therefore be one your tests support. If testing shows that only line drying keeps the leggings in shape, the label should say so.

Decide with the product in mind

Activewear customers often machine-dry everything. A fabric that tolerates low tumble drying may be worth more to your returns rate than a slightly cheaper one that needs line drying. Weigh the test results against how your customers actually care for the product.

Whatever you decide, record the tested drying condition, the growth and recovery results and the approved fabric reference together. When the next lot arrives, you can check it against the same numbers instead of waiting for reviews.

Sources and further reading

Standards and rules are summarised from their published scope or official guidance. Use the current edition and confirm requirements for your market.

Three perspectives on this question

Knitwear Base Editorial Team
Purchasing perspective

I'd ask the mill for recovery data after heat exposure, if it has any, on the exact fabric reference. If two candidate fabrics differ in price, the after-drying results tell me whether the difference is worth paying.

Knitwear Base Editorial Team
Merchandising perspective

Changing to 'line dry' is a real trade-off for gym customers. If we have to, I would explain it on the product page and hangtag, not only on the sewn-in label, so fewer customers get caught out.

Knitwear Base Editorial Team
QC perspective

We'd run the before-and-after tests on retained bulk from the returned lot and on the approved sample. If bulk recovers worse than the approved sample, it is a production deviation, not a care issue.

Working on a similar program?Send your tech pack, fabric references and test requirements. We reply with a quote and the questions we need answered.

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