How to Sew Polyester Fabric? Sewing Tips

You won’t have any trouble at all sewing polyester clothing with a little practice and our advice.

You will undoubtedly have some questions about how to use polyester if this is your first time working with it. What sewing machine tension do you need, what size needle should you use, and—and this is the big one—can you even sew it at all?

If you don’t know the proper methods, sewing with polyester can be challenging, but there are a few things you can do to make it simpler.

Table of Contents

How to Sew Polyester on a Sewing Machine?

Whether you’ve never sewn before or have been sewing for years, you’ll need to modify your usual techniques when sewing polyester.

Further Reading: How to Fix Snags in Polyester Fabric?

Our best advice is to make a sincere effort to understand how a sewing machine works. This will make it easier for you to understand what each setting actually does and will greatly improve the efficiency of all your sewing endeavors.

Machine Settings

How to Sew Polyester Fabric? Sewing Tips

Keep in mind that you’ll need to modify your typical sewing technique to meet its unique requirements if you’re new to sewing with polyester or sewing in general.

Stitch settings: Stick to a stitch length of 0.5 millimeters (0.020 in) to 1.5 millimeters (0.059 in) when using the suggested sewing machine setting for the best outcomes.
Needle: With polyester, the most efficient needle is a new one in the smallest size. The nicks and protrusions on worn-out needles have the potential to snag tiny polyester fibers, resulting in tearing and puckering. Larger-than-usual needles have the potential to weaken a seam and leave visible, unsightly holes. The problem is particularly common with knit polyester fabrics.
Thread: Polyester thread has the same elasticity as your fabric. When using polyester thread on a sewing machine or serger, wind the bobbin loosely and sew at a slow to moderate speed to avoid the thread feeding too quickly. The polyester thread may stretch due to the extreme friction brought on by improper threading. This stretched fiber will contract when it is cooled, leaving you with permanent seam bunching.
Tension: The upper tension will typically be around a 4 as a general rule. Before beginning, test out a few stitches on some scraps if you’re unsure that the machine is set up correctly.

The Fabric

Last but not least, be sure to pay attention to the percentage of polyester in your fabric. There are some 100% polyester fabrics available, but the majority of polyester fabrics are poly blends.

The most crucial thing to keep in mind is to use a polyester thread when working with 100% polyester. Your thread and fabric should have comparable elasticity. Otherwise, the thread won’t match the fabric’s strength and degree of stretch, which could lead to issues like increased wear, popped seams, and more.

To accommodate the increased flexibility of the spandex when sewing a polyester/spandex blend, it is best to use a stretch needle. The fibers are less likely to be harmed by ballpoint needles, so they also work well. Due to the tendency of spandex to shrink after the first wash, washing is essential before sewing.

How to Hand Sew Polyester?

The preferred technique is typically to sew polyester with a sewing machine. Polyester can, however, be completely hand-sewed. Simply some practice, persistence, and the right equipment are required. To remove any excess colorant or coating from the fabric before machine sewing, just like with polyester, it’s crucial to wash the fabric first.

Keep in mind that fabrics made of polyester, particularly those that are silky, are very slippery. Uneven stitches may result from difficulties maintaining control of the fabric. Spraying starch on your fabric before sewing will help you avoid this issue. To prevent buildup, you should wash your clothing before wearing it.

You should use a size 5–10 ballpoint hand-sewing needle for your needles. You’ll need a larger needle if your fabric is thicker and heavier. Additionally, you must use polyester thread of the highest caliber.

Making tiny, incredibly narrow zigzag stitches is what we advise doing for the actual stitches. To the point where they almost form a straight line, your zig-zags should appear narrow. Stronger holds will be provided by zigzag stitches, which are typically also simpler to sew evenly.

How to Sew Polyester Without Puckering?

You might find it challenging to prevent puckering when sewing with satin polyester. Fortunately, there are a few things you can do to lessen the dreaded wrinkle. Even the most experienced sewer can run into this issue.

Try different needle sizes, stitches, tensions, and other things by purchasing enough fabric to give you plenty of scraps to experiment with. When it comes time to actually sew the fabric, you should already have enough experience from your tests to know what sewing method will be most effective.
Avoid the temptation to use just any needle. Polyester works best with as fine a needle as possible—a size 8 “Sharp” or “Microtex” needle is one of the best to try.
To sew the seam, use tiny, narrow zigzag stitches.
Instead of laying the pieces out lengthwise, go with the cross grain.
Cut back on the sewing machine’s pressure. If you apply too much pressure while sewing, the fabric will pull and pucker. For the best chances of success, lower the pressure before you begin sewing.

Tips for Perfectly Sewing Polyester Fabric

Here are some additional tips to help you sew polyester fabric like a pro:
Use a walking foot; this will stop the fabric from shifting or stretching as it is fed through the machine on an even basis.
Use a foot that presses more lightly. The fabric won’t snag or become stuck if the pressing foot is lighter.
Implement a fabric stabilizer. A fabric stabilizer can aid in preventing stretching or puckering of the fabric.

Can You Sew Ripped Polyester?

Polyester can sometimes rip if it is put under enough stress, despite being known for its durability. Repairing the torn edges will at least give you a garment that is still usable even though you can’t return the item to its original state.

Purchase a small piece of polyester fabric that is as similar in color and weight to the ripped item as you can.
Measure and cut a piece of the purchased fabric. It ought to be an inch longer and one inch wider than the tear.
If the torn garment is lined, use a seam ripper to remove the lining close to the tear and push it away from the damage.
Under the tear on the inside of the garment, place the new piece of fabric. To attach the fabric to the garment, gather the torn edge.
To make sure the repair holds, set the sewing machine to a wide zigzag stitch and sew several lines over the tear.
Trim away any extra new fabric that is present beneath the tear after cutting the threads. Enough space should be left around the stitching of about.75 inches. Remove the pins.
Reinstall the lining, then secure it with pins. To secure the lining permanently, use a hand slip stitch.

Conclusion: Sewing Polyester Fabric

Even seasoned seamstresses sometimes struggle when sewing polyester. Fortunately, there are a few tricks, tools, and techniques you can use to make sewing this synthetic fabric simple.

Your next poly project should be a breeze now that you’ve hopefully learned enough tips and tricks. Please feel free to share the post if you think any of the advice might be helpful to your fellow crafters.