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Velour

Velour is a plush, soft-textured knit fabric with a velvety pile surface, distinguished by its smooth finish, subtle sheen, and inherent stretchiness, making it a versatile member of the pile fabric family. Unlike the woven structure of velvet, velour is produced through knitting, resulting in greater durability, flexibility, and ease of care while offering a luxurious tactile experience at a more accessible cost.^[1]^[2] The term velour derives from the French word velours, meaning velvet, and the fabric originated in France during the 19th century as an affordable, practical alternative to traditional silk velvet, surging in popularity during the 1970s for its use in casual and athletic apparel such as tracksuits.^[3] It is primarily composed of synthetic or natural fibers, including polyester for added sheen and durability, cotton for breathability and softness, or blends that combine these qualities, sometimes with a small percentage of spandex (typically 5-10%) to enhance elasticity.^[1] Key properties of velour include its exceptional softness, warmth, moisture absorption (particularly in cotton variants), wrinkle resistance, and abrasion durability, which contribute to its longevity in everyday use.^[1] These attributes make it ideal for a range of applications, from fashion items like loungewear, dancewear, and baby clothing to home décor such as upholstery, curtains, and automotive interiors.^[4]

Definition and Characteristics

Definition

Velour is a plush textile derived from the French word velours, meaning "velvet," which traces its linguistic roots to Old French velor and ultimately to the Latin villosus, denoting something shaggy or hairy in reference to its textured surface.^[5] Over time, the term evolved from simply denoting velvet-like materials to specifically identifying a distinct type of knitted fabric, distinguishing it in textile nomenclature in the mid-19th century.^[1] At its core, velour consists of a knitted fabric with a short, dense cut pile on one side, forming a soft, plush surface that mimics the luxurious feel of velvet while incorporating the elasticity typical of knits.^[1] This pile is created through a knitting process that loops yarns to form the base structure, with additional pile yarns cut to length for the characteristic nap.^[2] A primary distinguishing feature of velour is its knitted construction, in contrast to the woven pile of traditional velvet, which imparts inherent stretch and flexibility suitable for form-fitting garments and upholstery.^[2] This structural difference arose in the 19th century, particularly around the 1840s, when velour emerged as a more affordable and accessible alternative to the labor-intensive woven velvet, leveraging advances in knitting technology to broaden its appeal.^[1]

Physical and Chemical Properties

Velour fabric is characterized by its soft, plush pile that creates a smooth, velvety surface on the face side, while the reverse often features a knitted backing that provides structural support and enhances overall stability.^[1] This texture offers a luxurious tactile experience, though synthetic variants like polyester may feel slightly coarser compared to those made from cotton.^[1] In terms of durability, velour exhibits high abrasion resistance, outperforming traditional velvet due to its knitted construction, which imparts good elasticity and tensile strength. For instance, certain upholstery-grade velour fabrics can withstand over 100,000 Martindale abrasion cycles, making them suitable for high-traffic applications.^[1]^[6] Breathability in velour is moderate, allowing for comfortable air circulation without excessive airflow, with cotton blends particularly effective at wicking moisture away from the skin to promote dryness.^[7] This property stems from the fabric's knit structure and fiber composition, though denser piles may slightly reduce permeability compared to smoother knits.^[7] Chemically, synthetic velour versions demonstrate strong resistance to fading from light exposure, thanks to the inherent stability of polyester dyes under UV conditions.^[8] Natural fiber variants, such as those from cotton, render them gentle and skin-friendly without irritating sensitive areas.^[9] The pile structure of velour traps air effectively, providing notable thermal insulation and warmth retention, which enhances comfort in cooler environments.^[10] This insulating quality is particularly pronounced in thicker or blended compositions, contributing to its use in apparel and upholstery.^[4]

Production

Manufacturing Process

The manufacturing process of velour begins with the knitting stage, where circular or flat knitting machines are used to create a base fabric featuring looped yarns that form the foundation for the pile. During this phase, pile yarns are interlocked with the ground yarns to produce a terry-like structure, providing the fabric's characteristic elasticity and plush potential.^[11]^[12] Following knitting, the fabric undergoes napping and shearing to develop its distinctive cut-pile surface. Napping involves brushing the fabric with wire-covered rollers or teasels to raise the looped yarns into a soft, uniform pile, enhancing the tactile luxury. Shearing then trims the raised pile to a consistent length, typically 1-3 mm, creating the smooth, velvety effect while removing irregularities.^[13]^[11] Dyeing and finishing follow to impart color and durability. Reactive or disperse dyes are applied for excellent colorfastness, depending on the fiber type, with the process often conducted in high-temperature, high-pressure environments to ensure even penetration. For synthetic-based velour, such as those using polyester, heat-setting stabilizes the structure to prevent shrinkage, while calendering presses the fabric between heated rollers to achieve a smooth, glossy surface.^[12]^[14] Quality control is integral throughout production, with inspections focusing on pile uniformity, color consistency, and defect detection. Standards such as ISO 3801 guide the measurement of mass per unit area, which for velour typically ranges from 200-400 g/m², ensuring compliance with performance specifications.^[15] The dyeing stage is notably water-intensive, consuming significant volumes per unit of fabric and generating effluent laden with dyes and chemicals. Modern low-impact methods, including high-fixation dyes and closed-loop systems, can reduce effluent volume and pollution by 30-50% compared to traditional processes.^[16]^[17]

Materials and Fibers

Velour fabric is commonly made from polyester as the primary synthetic fiber, offering durability, wrinkle resistance, and ease of care, which contribute to the fabric's longevity and low maintenance. Cotton is used as a natural fiber, prized for its absorbency and soft base that enhances comfort and breathability in the final product.^[1]^[12] Blends, such as those incorporating spandex, introduce stretch properties that improve fit and flexibility, particularly in activewear applications.^[12] Common composition ratios vary by intended use; for instance, activewear velour often features approximately 93% polyester and 7% spandex to balance durability with elasticity.^[18] Traditional velour versions may consist of 100% cotton for a more natural feel and higher absorbency, though such pure compositions are less common in modern production.^[19] Cotton for velour is sourced from conventional farming or organic cultivation, with organic variants promoting reduced pesticide use and better soil health.^[12] Recycled polyester, derived from post-consumer plastic bottles, enhances sustainability by decreasing reliance on petroleum-based raw materials and cutting energy consumption by 30-50% compared to virgin polyester.^[20] These eco-friendly options in velour production can lower the fabric's overall environmental footprint while maintaining performance qualities.^[21] In fiber processing, yarns for velour are selected to ensure a soft texture, with specifications influencing the fabric's drape and pile density, affecting its tactile appeal and durability.^[1] Synthetics like polyester generally lower production costs for velour, estimated at $6-24 per square meter, due to efficient manufacturing and raw material availability, whereas natural cotton variants range from approximately $24-60 per square meter owing to higher cultivation and processing demands.^[22] These material choices directly impact the fabric's resilience, as detailed in analyses of physical properties.^[12] As of 2025, velour production increasingly incorporates digital technologies for customized designs and enhanced sustainable practices to meet modern environmental standards.^[23]

History

Origins and Early Development

The term velour derives from the French "velours," meaning velvet, which traces back to Old French "velor" (or "velos") and ultimately to Latin "villosus," denoting a shaggy or hairy texture. This linguistic root links velour to the broader tradition of pile fabrics, with velvet production emerging in Europe by the 14th century, particularly in Italy and France, where silk weavers developed techniques for creating plush surfaces.^[5]^[24] Early forms of velour appeared in the 19th century, particularly from the 1840s, as a knitted alternative to costly woven velvet, developed in France to mimic the luxurious pile at a lower expense. Cotton-based velour gained traction as an accessible imitation, marking the fabric's shift from artisanal to more widespread production.^[1]^[25]^[26] The industrial era catalyzed velour's development in the mid-19th century, as mechanized power looms and knitting innovations adapted velvet's pile-forming techniques to knitted structures, enabling efficient mass output. Patents for advancements in pile fabric machinery, including those for knitting-related processes, proliferated around the 1850s, facilitating the production of durable, looped knits. In France, textile mills in Lyon played a pivotal role, leveraging the city's established silk expertise to refine pile textiles and solidify velour as a recognized category by 1870.^[1]^[27]^[28] During the Victorian era, velour found initial applications in theatrical costumes and as an economical option for upscale garments, offering a soft, velvety aesthetic to middle-class consumers without the prohibitive cost of silk velvet.^[1]^[25]

20th Century Popularity and Evolution

The introduction of synthetic fibers like polyester in the 1950s revolutionized velour production, shifting it from traditional cotton-based knits to affordable blends that facilitated mass manufacturing in the post-World War II era.^[29] This innovation, driven by companies such as DuPont with their Dacron fiber, allowed velour to transition from niche upholstery applications to broader accessibility, as polyester's durability and low cost reduced production expenses and enabled widespread distribution.^[30] By blending polyester with cotton or rayon, manufacturers achieved a plush texture that retained velour's signature pile while improving wrinkle resistance and ease of care, marking a key evolution toward everyday use.^[31] Velour's popularity surged in the 1960s and 1970s, aligning with the era's embrace of casual, expressive fashion amid social rebellion against formal attire.^[31] Iconic applications included leisure suits and tracksuits, which became staples of disco culture, often featuring bold colors and loose silhouettes popularized by sportswear brands like Adidas in their velour jogging suits.^[31] Celebrities such as the Bee Gees amplified this trend by incorporating velour into stage outfits, positioning the fabric as a symbol of modern, hip leisure that blended comfort with a touch of extravagance.^[31] In the counterculture context, velour represented casual luxury, offering an accessible alternative to high-end silks while evoking a sense of relaxed opulence in everyday and nightlife settings.^[31] By the late 20th century, velour adapted to emerging athletic trends through integrations like spandex blends in the 1980s, enhancing stretch and functionality for activewear such as tracksuits and sportswear.^[32] This shift coincided with a decline in its use for formal fashion, as conservative styles resurged, but velour maintained relevance in home textiles and upholstery, where its durable pile continued to provide a soft, luxurious aesthetic for furnishings.^[31]

Types and Variations

Common Types

Velour fabrics are categorized by their composition, which influences the pile finish and suitability for specific purposes, ranging from apparel to home furnishings. Common variants include those made primarily from natural fibers for softness, synthetic blends for enhanced functionality, and specialized finishes for durability or aesthetics. These types maintain the characteristic soft pile of velour while adapting to diverse needs through variations in weight, stretch, and processing. Cotton velour consists of 100% cotton, providing a natural softness and breathability that makes it ideal for gentle applications like baby clothing and loungewear.^[12]^[1] Its pile finish is achieved through knitting and shearing, resulting in a plush texture that absorbs moisture effectively.^[1] Stretch velour incorporates blends of cotton, polyester, or rayon with spandex to introduce elasticity for form-fitting garments such as activewear and dresses.^[33]^[34] The spandex content enhances recovery and flexibility, with the pile finish retaining a soft, velvety surface despite the added movement.^[35] This composition balances durability and comfort, making it popular for items requiring both drape and support.^[34] Polyester velour is made primarily from synthetic polyester fibers, offering added sheen, durability, and wrinkle resistance compared to natural variants. It is commonly used in apparel and upholstery for its cost-effectiveness and ease of maintenance.^[1]^[4] Crushed velour features a textured pile created by crushing or embossing the fabric after knitting, providing a unique, patterned appearance while preserving the soft feel. This variant is suitable for fashion and decorative applications.^[4] Upholstery velour typically uses polyester or cotton blends with a reinforced backing to enhance durability for furniture and curtains.^[36]^[37] The backing prevents pilling and wear, supporting high-traffic environments. The pile finish is denser and more resilient, contributing to a luxurious yet practical surface for seating.^[38] Printed velour undergoes digital printing after the shearing process to apply intricate patterns, allowing for vibrant, customized designs on the pile surface without altering the base composition.^[39] This technique ensures colorfastness and detail retention, suitable for decorative or fashion-oriented variants derived from cotton or synthetic bases.^[40] The post-shearing application preserves the fabric's softness while enabling diverse aesthetic finishes.^[41]

Comparisons to Similar Fabrics

Velour is distinguished from velvet primarily by its construction method; while velour is typically knitted, providing inherent stretch and durability suitable for activewear and casual garments, velvet is woven, resulting in a more rigid structure that offers less elasticity and a more formal appearance.^[42]^[43] Velvet's pile is usually created through a cut-pile weaving process, often featuring uncut loops in some variants for added texture, whereas velour's pile is uniformly cut and shorter, contributing to its smoother, less lustrous finish.^[43]^[44] In comparison to velveteen, velour offers greater flexibility due to its knitted base, which allows for better movement and shape recovery, whereas velveteen is a woven cotton fabric with a short, dense pile that tends to fray more easily along edges and lacks the stretch needed for form-fitting applications.^[45]^[46] Velveteen's pile is formed by filling yarns in a weft direction, giving it a matte, sturdy texture ideal for upholstery but less versatile for apparel than velour's adaptable knit structure.^[47] Velour differs from plush in pile length and application focus; plush features a longer, often uncut pile that creates a softer, more voluminous texture suited for stuffed toys and heavy upholstery, while velour's shorter, cut pile provides a sleeker surface better adapted for clothing and lighter furnishings.^[48]^[49] This distinction makes plush more prone to matting under frequent handling compared to velour's more resilient, even nap.^[49] Unlike fleece, which is a non-piled, brushed synthetic knit fabric prized for its insulation and lightweight warmth without a defined pile texture, velour incorporates a distinct pile that imparts a luxurious, velvety handfeel, though it is generally less insulating and more focused on aesthetic drape than fleece's practical thermal properties.^[50]^[51] Fleece, often made from polyester, excels in moisture-wicking and quick-drying for outdoor use, contrasting velour's emphasis on softness and visual appeal in indoor or fashion contexts.^[50] Overall, velour's knitted foundation confers superior drape, elasticity, and recovery from stretching compared to the woven alternatives like velvet and velveteen, enabling broader use in dynamic applications while maintaining a plush aesthetic that sets it apart from non-piled options like fleece.^[43]^[45]

Uses and Applications

In Fashion and Apparel

Velour has been a staple in activewear since the 1970s, particularly in tracksuits and joggers, where its stretch properties enhance comfort during movement.^[52] The fabric's introduction of warming stretch variants during this era made it ideal for casual athletic pursuits, offering a plush feel that combined functionality with style.^[52] Modern stretch velour often incorporates spandex for 4-way stretch, allowing full range of motion while maintaining a soft, supportive drape suitable for loungewear and light exercise.^[53] In casual fashion, cotton velour excels in everyday garments like sweaters, dresses, and robes, prized for its inherent softness and breathability that provides all-day comfort.^[54] These pieces leverage the fabric's smooth pile to create relaxed silhouettes, such as oversized sweaters or flowy dresses, ideal for lounging or informal outings.^[55] The material gained cultural prominence in the 1990s through hip-hop influences, where velour tracksuits and similar casual items symbolized street style and accessibility.^[56] High-end fashion incorporates printed velour for evening wear and costumes, utilizing its textured pile to add depth and contrast against intricate patterns. This use highlights velour's versatility in creating visual interest through its subtle sheen and tactile quality, often in form-fitting gowns or theatrical attire. Proper care is essential to maintain velour's appearance in apparel, with machine washing recommended on a gentle cycle at 30°C using mild detergent to avoid damaging the pile.^[57] High heat from dryers should be avoided, as it can flatten the nap and cause uneven wear; air drying flat preserves the fabric's loft and shape.^[58] Quality blends, such as those with polyester or spandex, exhibit low shrinkage rates when following these guidelines, ensuring longevity in wear. The 2020s have seen a resurgence of velour in athleisure, as of 2025 driven by demand for comfortable, versatile pieces that blend sport and casual aesthetics.^[59] This trend aligns with the broader athleisure market's growth, where pile knits like velour contribute to soft, elevated loungewear options popular in post-pandemic wardrobes.^[60]

In Furnishings and Other Industries

Velour finds extensive application in upholstery for residential and commercial furnishings, where its plush texture and durability make it ideal for sofas, chairs, and curtains. Heavy-duty variants, often made from polyester or cotton blends, provide a luxurious feel while withstanding daily wear in high-traffic areas. These fabrics are frequently treated with flame-retardant finishes to comply with safety standards such as NFPA 701, ensuring they remain fire-resistant even after repeated washing, which is essential for public spaces like hotels and restaurants.^[61]^[62] In the automotive industry, synthetic velour is commonly used for seat covers and interior trim in luxury vehicles, offering a soft, elegant surface that enhances passenger comfort without compromising on performance. Polyester-based velour provides abrasion resistance and water-resistant properties that protect against spills and stains, contributing to its popularity in premium car models.^[63] Theatrical and event productions rely on velour for stage curtains and masking drapery, leveraging its dense pile for superior light absorption in blackout configurations. Blackout variants can block up to 99% of light, creating immersive environments for performances by minimizing unwanted illumination and glare. Flame-retardant treatments are standard in these applications to meet venue safety requirements, with the fabric's weight and nap direction optimized for seamless installation and acoustic damping.^[64]^[65]^[66] Beyond these sectors, velour serves niche roles in medical and toy manufacturing. In healthcare, polyester velour is used for scrub linings and jogger-style pants, providing softness and breathability. For toys, hypoallergenic velour linings, often from cotton-polyester mixes, ensure a gentle, plush interior that avoids common allergens like dust mites, making it safe for children's stuffed animals and dolls.^[67]^[68] Sustainability efforts in velour applications emphasize recyclable polyester variants for furnishings, which can lower environmental impacts compared to traditional leather alternatives. Lifecycle assessments indicate that recycled polyester velour reduces resource depletion and emissions by incorporating post-consumer waste, through decreased water use and landfill contributions. These eco-friendly options align with circular economy principles, enabling end-of-life recycling in industrial settings.^[21]

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How to Care for Stretch Velour - Montreux Fabrics
Aug 25, 2025 · Gentle wash: Use a cold or lukewarm wash (30°C is ideal) to protect the fibres and the pile. • Delicate cycle: If machine washing, choose a ...Missing: high preservation shrinkage rate
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How to Clean Velour Fabric: Step by Step Guide - F&A Fabrics
Feb 26, 2025 · Hand wash or machine wash on a gentle cycle with cool water, then air dry flat to maintain softness and shape. After drying, brush velour gently ...Missing: C rate
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https://www.fredkriegerfabrics.com/cotton-velours
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2025 Tracksuit Trends: Market Growth & Top Styles Revealed - Accio
Sep 4, 2025 · Discover why tracksuit trending dominates 2025 fashion! Explore seasonal demand spikes, sustainable styles, and top-performing products.
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Athleisure's Rise Explained: Success In Fashion - Heuritech
Jan 16, 2024 · The athleisure sector has grown 42% in the last seven years, and by 2026, it is expected to reach a value of over $250 billion. Technological ...Athleisure Wear: The Street... · Athleisure: From Key... · Indie Activewear Brands...Missing: velour | Show results with:velour<|control11|><|separator|>
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https://www.weircrafts.com/product/cotton-plush-nicky-velour-fabric/
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https://begoodtex.com/product_category/sofa-fabric/
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IFR Fire Velvet Fabric for Stage, Events, Upholstery, Hospitality
IFR Fire Velvet is 100% flame-retardant polyester, 60" wide, 57,000 rubs, soft, durable, and suitable for commercial upholstery and high-traffic areas.Missing: curtains treatments
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Water Repellent Velvet Upholstery, Flame Retardant Fabric ... - Etsy
Rating 5.0 (37) Fireproof: Complies with strict standards (BS 5852 0&1, NFPA 701, M1, EN 13773...) Ultra resistant: Martindale test 55,000 revolutions – intensive use
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https://www.shearcomfort.com/Velour-Seat-Covers.asp
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https://www.rosebrand.com/subcategory471/black-curtains-masking.aspx
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Cotton Velour | Main Stage Drape - Fred Krieger Fabrics
Cotton velour is still one of the most popular theater fabrics used for stage curtains. It has a rich, dense pile making its light absorbing characteristics ...
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https://www.canvasetc.com/product/velour-stage-curtains-60-black/
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https://www.scrubsselect.com/products/med-couture-amp-velour-jogger-scrub-pant-mc107
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Velvet Toy Fabric - 100% Polyester Soft Plush Material - Alibaba
Hypoallergenic Properties: Many synthetic velvet fabrics are resistant to dust mites and allergens, making them a safer choice for sensitive children. Vibrant ...
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https://www.weircrafts.com/product/cotton-plush-nicky-velour-fabric/
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[PDF] Life Cycle Assessment of Leather and Leather-Like Materials
The results show that bovine leather has the highest environmental impact, mainly due to a high carbon footprint, toxicity potential and water use. PU leather ...