5 Best Fabrics for Men’s Underwear

When it comes to sewing men’s underwear, look for cotton, polyester, or nylon blends. Cotton is hypoallergenic and helps control moisture, while polyester is moisture wicking, and nylon is very soft and often form fitting. Adding a Lycra or spandex blend into polyester or cotton helps ensure a wider range of motion and movement, which also ensures comfort. Cotton and polyester are both hard wearing fabrics and really hold up, with the added bonus that they are easy to launder.

Best Fabrics for Men’s Underwear

Here are our men’s underwear fabric reviews.

1. Robert Kaufman Mammoth Flannel

Robert Kaufman Mammoth Flannel

This fabric is 100% cotton. Cotton is generally very durable, easy to care for, and is usually soft and comfortable. Perhaps one of the best benefits of using cotton for underwear is the way that it controls moisture and breathes. Cotton is also hypoallergenic, which is a great added benefit when using it for making underwear.

  • The collection comes in a WIDE variety of different patterns and colors
  • Lightweight fabric and incredible soft
  • Quality fabric for a budget price
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2. 40 Denier Tricot

40 Denier Tricot

This fabric is 100% nylon and is very lightweight. Nylon is generally very soft and fits well. Nylon is strong and stands up to wear and tear and launders easily and well. Nylon is known for its high elasticity, which makes it a good choice for sewing underwear.

  • Can be used as a lining in conjunction with other fabrics
  • This fabric features 50% stretch across the grain
  • Comes in a wide variety of colors for customization
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3. 2×1 Rib Knit

2x1 Rib Knit

This fabric is the perfect blend when it comes to underwear. Polyester is a popular choice when it comes to sewing underwear and nylon and spandex help with stretch and comfort. This fabric is both incredibly lightweight and very soft. It would be great for sewing underwear or even long underwear.

  • Features 30% stretch across the grain
  • Polyester is naturally moisture wicking and nylon helps with a snugger fit
  • Polyester fabrics are durable and are generally easy to launder
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4. Double Brushed Poly Jersey Knit

Double Brushed Poly Jersey Knit

Underwear doesn’t have to be boring. Many companies are making men’s underwear in fun, funky prints. The price tag associated with these prints is usually on the pricier side, so why not try making them at home? This jersey knit fabric is incredible soft and lightweight. The polyester, Lycra blend wicks moisture and allows for greater stretch.

  • Features 50% stretch across the grain for added comfort and mobility
  • The fabric is durable and easy to launder
  • Comes in a HUGE variety of fun, trendy, funky patterns and prints
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5. Fabric Merchants Jersey Knit Solids

Fabric Merchants Jersey Knit Solids

This jersey knit is the perfect blend of cotton and Lycra spandex. Cotton is durable, while Lycra spandex adds that extra stretch needed for flexibility. The fabric comes in many different colors for a higher degree of customization. It is easy to launder and care for.

  • Cotton helps control moisture and is hypoallergenic
  • Lightweight and features 40% stretch across the grain
  • Soft and perfect for many other apparel sewing projects to help reduce waste
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Men’s Underwear Fabric Buying Guide

Men’s underwear can be quite pricey, depending on what brand and what material the underwear is made of and where it’s purchased. Why not buy your own fabric and make it yourself? When you purchase your own fabrics, you can get the blend of materials that you’d like with your specific purpose in mind. Buying fabric and sewing underwear yourself ensure that you get a higher degree of customization.

Trendy VS. Plain Prints

There are ever increasing lines of men’s underwear that come out with novelty or fun prints. These underwear especially can be expensive. It would be much more fun to buy fabrics in prints that you choose yourself and make your own customized underwear. Make something just as fun and funky as what all those major brands are putting out. Or, if you’re not into fun and funky, you can choose more traditional, plain prints.

Generic or Customizable

When it comes to buying fabric for sewing men’s underwear versus just buying generic pairs from the store, making your own underwear allows for a higher degree of customization in that you can pick your blend of materials and your prints, but you’ll also get a tailored, custom fit that stores can’t offer. Many fabrics can be purchased for a budget price, which makes customization even more attractive in comparison to buying generic, store bought pairs that might not fit properly. The price of generic underwear might be attractive, but the price of customized comfort can’t really be bought.

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