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Sewing PUL and Barrier Fabrics


Barrier fabrics are designed to provide a leak and non-wicking barrier.  Depending on the application, special preparation and sewing techniques should be observed. 

Fabric Preparation

Both .PUL and ProCare fabrics are cut & sew ready and SHOULD NOT be pre-washed. 

PULs are are susceptible to surface abrasion and wringing damage when washed as unsewn cuts and yardage.  Wringing damage is a leading cause of barrier wicking and leaks -- it may visible, it may also be microscopic and impossible to see. 

If you need to wash your items prior to use or delivery to your customers, wash the completed garments.  PUL stabilized against wringing damage once it is sewn into a garment.    

Needle Selection

Ballpoint or stretch needles only.   Never use sharp or leather punching needles as the yse will damage the knit substrates. 


Pinning should always be done outside the barrier area to avoid unwanted perforation to the  to the barrier.  Paper clips, spray starch or sewing spray adhesives and basting tapes are other options, these will hold your fabrics together for sewing. 

Using a teflon coated sewing foot is recommended when sewing PUL.  It allows the fabric to move through the machine at good speeds and with minimal sticking.