Non woven fabric material is redefining how businesses approach textile sourcing for industrial applications, healthcare, packaging, and hygiene solutions. Unlike woven fabrics or knitted textiles, non woven fabrics are manufactured by bonding fibres together using several methods such as thermal processes, chemical processes, or mechanical bonding. The result is a lightweight, breathable, durable fabric alternative to traditional textiles, valued for its specific characteristics, versatility, and cost-effectiveness.
This comprehensive guide explores how non woven fabric material is made, its key properties, how it compares to woven fabrics, and why it has become an essential resource for numerous applications across business industries.
The Evolution of Non Woven Fabrics Across Modern Industries
Non woven fabrics have advanced significantly in recent decades, driven by innovation, environmental considerations, and growing demand for durable fabric alternatives to traditional textiles in industries requiring scalable, high-performance solutions.
Early Origins
The earliest non woven materials, such as felt, were produced by pressing staple fibres together to form dense, protective fabrics for insulation, clothing, and shelter. Although primitive, these early fabrics set the foundation for today’s engineered non-wovens, which meet stringent industrial and technical requirements.
The Rise of Synthetic Fibres
The development of synthetic fibres such as polyester and nylon in the 1930s and 1940s revolutionised non woven fabric material production. These materials offered greater durability, consistency, and cost effectiveness, allowing manufacturers to produce lightweight, breathable, and versatile non woven fabrics for a wide range of uses.
Spunlaid and SMS Fabrics Breakthrough
The introduction of the spunlaid process marked a major step forward. In this process, continuous long fibres are spun onto a conveyor belt, forming a nonwoven web that is later bonded together using thermal, chemical, or chemical mechanical methods.
Building on this, SMS fabrics—a new generation of materials—combine spunbond, meltblown, and spunbond layers. This combination enhances durability, breathability, and barrier protection, making SMS fabrics essential in sectors like healthcare, hygiene, packaging, and industrial applications.
Modern-Day Non Wovens: Performance Meets Versatility
Today, non woven fabric materials are indispensable across industries, appearing in:
- Disposable clothing
- Surgical masks and face masks
- Reusable shopping bags and promotional items
- Protective packaging
- Industrial filtration products
- Geotextiles for construction
The versatility, cost effectiveness, and scalable production capabilities of non woven fabrics make them a preferred solution for businesses that prioritise performance and sustainability.
How Non Woven Fabric Material Is Manufactured
Producing non woven fabric material involves advanced, efficient manufacturing processes that meet the demands of modern industries for reliability, durability, and customisation.
Raw Material Selection
Most non woven fabrics are made using:
- Polypropylene (PP) — valued for its strength, water resistance, and affordability
- Polyester (PET) — offers excellent durability, resilience, and temperature stability
- Staple fibres and continuous filament blends — provide enhanced softness and versatility
In response to environmental demands, many manufacturers now incorporate biodegradable alternatives like PLA (polylactic acid) and viscose, offering eco-conscious product lines without compromising performance.
Web Formation
The web formation stage involves laying fibres onto a conveyor belt to create a nonwoven web. These fibres can be arranged:
- Isotropically (random orientation) for uniform strength
- Anisotropically, in one direction, for tailored performance based on the end-use application
Precise control over web formation allows for consistent material quality, specific characteristics, and strength-to-weight ratios suitable for various industrial products.
Bonding the Fibres
The nonwoven web is then bonded together through several methods, each contributing to the final product’s durability, functionality, and appearance:
- Thermal bonding: Uses heated rollers, hot air, and thermal processes to fuse fibres into a strong, uniform material — ideal for high-speed, high-volume production
- Chemical bonding: Involves adhesives or solvent treatment, allowing for the application of performance-enhancing finishes like water repellency or flame retardancy
- Mechanical bonding: Utilises water jets or the needling process to entangle fibres physically, enhancing durability, texture, and fabric integrity
These manufacturing processes are selected based on the intended use, whether for disposable clothing, protective packaging, or high-performance industrial applications.
Finishing Treatments
To achieve optimal key properties, non woven fabrics undergo custom finishing treatments, including:
- Water repellency, often applied using silicone coatings (fluorocarbons are being phased out for environmental reasons)
- Flame retardancy, meeting Australian AS/NZS 1530 standards for textiles exposed to high temperatures
- Antimicrobial and non-toxic finishes for products intended for medical or food-contact applications
- UV resistance, extending durability for outdoor or demanding industrial applications
- Enhanced softness, breathable coatings, and skin-safe, non-irritating finishes for hygiene and healthcare products
These treatments allow manufacturers to tailor non woven materials to meet strict technical, environmental, and user-comfort requirements.
Final Inspection and Preparation
Before distribution, non woven fabric materials undergo rigorous inspection, including:
- GSM (grams per square metre) testing for weight and consistency
- Tensile strength and durability evaluation
- Pore size analysis for filtration and barrier performance
- Visual inspection to ensure uniformity and surface quality
Once approved, the materials are rolled, packaged, and shipped for numerous applications, ready to meet the performance expectations of business industries worldwide.
Types of Non Woven Fabrics and Their Characteristics
Business industries can select from a wide range of non woven fabrics, each with unique properties suited to specific technical and operational needs.
Spunbond Nonwoven Fabric
Spunbond non woven fabrics are manufactured using continuous filament, creating a lightweight, strong, and cost-effective material ideal for packaging, agriculture, reusable bags, and geotextiles.
Key Properties:
- High durability and tensile strength
- Customisable colours, UV-stabilised, and anti-static options
- Available in the GSM range of 10 to 150 grams per square metre
Meltblown Nonwoven Fabric
Meltblown nonwoven fabric uses ultra-fine fibres, delivering exceptional filtration performance. This makes it ideal for:
- Face masks, including surgical and N95 respirators
- Industrial air and liquid filters
- High-performance medical textiles
Key Properties:
- Fibre diameters of 1 to 5 microns for precision filtration
- Essential for surgical masks, compliant with AS/NZS 1716:2012
- Lightweight, breathable, with a typical GSM of 15 to 60
SMS Fabrics (Spunbond + Meltblown + Spunbond)
SMS fabrics, combining spunbond and meltblown layers, represent a new generation of non woven materials, valued for their strength, breathability, and barrier protection.
Key Properties:
- Multi-layered for splash resistance and microbial barrier
- Non-toxic, non-irritating, suitable for direct skin contact
- Compliant with EN 13795 for surgical gowns, drapes, and AS/NZS 1716
- Common in disposable clothing, protective covers, and medical packaging
Other Specialty Non Wovens
- Geotextiles: UV-stabilised, water repellent, and engineered for soil reinforcement, compliant with ISO 10319 standards
- Automotive Insulation: Flame-retardant nonwoven fabrics, designed for soundproofing and thermal management in vehicles
- Hygiene Products: Absorbent hydrophilic and moisture-resistant hydrophobic layers, commonly used in sanitary products and wipes
Essential Characteristics and Advantages for Business Industries
Non woven materials offer unmatched performance and flexibility for business operations:
- Lightweight, breathable, and protective across demanding environments
- High tensile strength and durable fabric construction for extended product life
- Customisable properties, including flame retardancy, water repellency, antimicrobial, and UV resistance options
- Certified non-toxic, non-irritating, skin-safe finishes, meeting OEKO-TEX® Standard 100
- Cost-effective production enables competitive pricing for disposable or high-volume products
For businesses seeking scalable, reliable textile solutions, non woven fabric materials deliver efficiency without compromising performance.
Sustainability Considerations for Non Wovens
As sustainability becomes a core priority for business operations, non woven fabrics have evolved to support environmental responsibility:
- Polypropylene non wovens are recyclable where appropriate infrastructure exists
- PLA-based non woven materials are compostable under EN 13432, requiring industrial composting facilities
- Water-based, solvent treatment coatings reduce environmental impact compared to older chemical formulations
- Compliance with APCO (Australian Packaging Covenant Organisation) ensures alignment with national waste reduction and circular economy initiatives
The ability to combine high-performance materials with eco-conscious features makes non-woven fabrics a strategic choice for businesses committed to reducing their environmental footprint.
Common Applications for Non Woven Fabrics
The versatility of non woven fabric material enables its use across diverse industries:
Eco-Friendly Bags and Promotional Packaging
- Reusable, branded non woven fabric materials support corporate sustainability goals
- Water repellent, durable designs extend product life
- Widely used in events, retail, and marketing initiatives
Food, Retail, and Hospitality
- Reusable shopping bags
- Protective food wraps maintain hygiene and freshness
- Disposable tablecloths and disposable clothing for catering and hospitality
Medical and Healthcare
- Surgical masks, respirators, and protective equipment compliant with AS/NZS 1716:2012
- Isolation gowns, disposable clothing, and sterile protective covers
- Sterilisation wraps with validated microbial barrier performance, meeting TGA and international standards
Industrial, Construction, and Heavy-Duty Applications
- Geotextiles for soil reinforcement, erosion control, and infrastructure protection
- Automotive insulation, soundproofing, and durable fabric protective layers
- Heavy-duty packaging and machinery protection
Smart Packaging and Technology-Integrated Solutions
- Lightweight, anti-static, protective packaging for electronics and sensitive goods
- Compatibility with RFID and QR-code technologies for enhanced traceability
- Advanced materials supporting logistics, product protection, and compliance
Woven vs Non Woven Fabrics: What Buyers Should Know
| Feature | Woven Fabric | Non Woven Fabric Material |
| Production Process | Interlaced yarn patterns | Bonded together via thermal processes, chemical, or mechanical methods |
| Durability | High, ideal for long-term use | Strong, often designed for disposable clothing or short-term needs |
| Cost | Labour-intensive, higher production cost | Cost-effective, scalable for bulk production |
| Applications | Apparel, upholstery, traditional textiles | Face masks, medical, packaging, industrial uses |
| Customisation | Through weaving patterns and material selection | Via fibre choice, finishes, coatings and specific characteristics |
Additional Clarifications for Buyers
1. Are Microfibre Cloths Nonwoven?
Yes, most are nonwoven fabrics, created by bonding fine fibres of polyester and polyamide, delivering superior absorbency, durability, and softness for cleaning, automotive, and industrial uses.
2. What is the Difference Between Non Woven Fabric and Cotton?
Cotton is a natural, woven fabric valued for softness and breathability in traditional textiles. In contrast, non woven fabric materials, typically synthetic, offer lightweight, breathable, and cost-effective solutions for packaging, medical products, and industrial protective gear.
3. Is Non Woven Better Than Polyester?
It depends on the application. Woven polyester offers durability for long-term textiles, such as upholstery and workwear. Non woven materials, including polyester variants, excel in disposable clothing, filtration products, and water repellent packaging where breathability, lightweight structure, and production efficiency are critical.
Why Choose Non Woven Fabric Materials for Your Business
Non woven fabric materials are a smart choice for businesses looking for reliable, durable, and cost-effective solutions for packaging, reusable products, and industrial applications. Their strength, breathability, and wide range of finishes make them ideal for high-volume use across retail, healthcare, agriculture, and other industries.
As sustainability becomes a greater priority, non woven fabrics offer practical options that help reduce waste and support eco-friendly business practices.
At Non Woven Bags Direct Australia, we specialise in supplying high-quality, custom-branded, wholesale non woven bags to businesses of all sizes. Whether you need reusable shopping bags, event bags, or promotional packaging, our bulk non woven bag solutions are designed to help your business stand out while supporting your sustainability goals.
Get in touch with our team today to order bulk non woven bags that are durable, affordable, and tailored to your business needs.