Covered yarn represents a pinnacle of textile engineering, combining the superior elasticity of a core filament with the protective and aesthetic qualities of a sheath yarn. This advanced composite yarn is fundamental to creating fabrics that offer both exceptional comfort and high performance. Understanding the types, properties, and applications of covered yarn is crucial for manufacturers and designers aiming to innovate in sectors ranging from everyday apparel to technical textiles.
This guide provides a detailed overview to inform your material selection process.
Types of Covered Yarn: An Overview
Covered yarns are systematically categorized along three primary technical dimensions: the elastic core material, the structural architecture of the wrapping, and the manufacturing technology employed. This multi-faceted classification system allows for precise engineering of yarn properties, ensuring that each variant delivers a unique combination of stretch, durability, hand feel, and performance tailored for highly specific end-uses across the textile industry.
Classification by Core Component
The selection of the core filament is the most critical decision, as it fundamentally dictates the yarn’s elastic character, recovery power, and long-term resilience. This core is the engine of the yarn’s stretch, and its material properties directly determine the performance ceiling of the final fabric.
- Spandex Covered Yarn: The most prevalent type, utilizing a spandex (elastane) core. It is prized for its exceptional stretch (up to 500-600%), high recovery, and durability against body oils and sweat. It is the go-to choice for high-performance activewear, modern fashion, and intimate apparel.
- Rubber Covered Yarn: Features a natural or synthetic rubber core. It delivers a powerful, robust elasticity and is often more cost-effective. Traditionally used in hosiery, waistbands, and foundational garments where extreme stretch under lower tension is required.
Classification by Yarn Structure
The number of wrapping layers is a key structural determinant that directly influences the yarn’s mechanical balance, visual integrity, and tactile qualities. This choice impacts everything from the yarn’s tendency to twist (torque) to its opacity when stretched, ultimately defining the quality and durability of the end product.
- Single Covered Yarn (SCY): The spandex or rubber core is wrapped with a single layer of sheath yarn. This results in a softer, more pliable yarn that is cost-effective to produce. A potential drawback is a slight tendency for torque and minimal “grin-through” (core visibility) under maximum stretch.
- Double Covered Yarn (DCY): The core is wrapped with two layers of sheath yarn, typically twisted in opposite directions. This process creates a perfectly balanced yarn with superior coverage, eliminating grin-through and minimizing spirality in knitted fabrics. It offers a denser, smoother feel ideal for premium applications.
Classification by Production Technology
The manufacturing methodology—whether using air-jet entanglement or mechanical twisting—imparts a distinct textural signature and a specific performance profile to the covered yarn.
- Air Covered Yarn (ACY): Produced using high-speed air jets that entangle the sheath fibers around the core without mechanical twisting. This results in a softer, bulkier, and more porous yarn with a gentle hand feel, excellent for lightweight, comfortable knits.
- Mechanical Covered Yarn (MCY): Manufactured using ring spindles or hollow spindle machines that physically wrap and twist the sheath around the core. This produces a firmer, more compact, and highly durable yarn with a sleek surface, ideal for structured fabrics and high-abrasion resistance applications.
Applications of Covered Yarn
Covered yarn, which wraps an elastic core like spandex with outer fibers such as nylon or polyester, finds primary use in stretchy, durable textiles requiring comfort and shape retention.
Covered Yarn Applications Overview Table
| Covered Yarn Type | Key Features | Main Applications |
| Spandex Core (Single Covered) | Soft hand feel, good elasticity, cost-effective. | Lightweight apparel, hosiery, basic knitwear. |
| Spandex Core (Double Covered) | Excellent coverage, balanced structure, no grin-through, superior recovery. | High-end activewear, swimwear, seamless garments, intimate apparel. |
| Rubber Core (Covered) | Powerful elasticity, high retractive force. | Socks, traditional waistbands, medical hosiery. |
| Air Covered (ACY) | Soft, bulky, lightweight, high comfort. | Premium casualwear, fine-gauge sweaters, comfortable base layers. |
| Mechanical Covered (MCY) | Firm, compact, high durability, sleek surface. | Shoe uppers, technical uniforms, elastic tapes, industrial fabrics. |
Detailed Applications by Category
Apparel & Fashion
- Typical Products: Denim, trousers, dresses, t-shirts, and tailored jackets.
- Key Yarn Features: “Comfort stretch” that allows for ease of movement without bagging; improved fit and silhouette; wrinkle resistance.
- Recommended Yarn Types: Single or Double Covered Spandex Yarn with cotton or polyester sheaths. For a premium soft hand feel, Air Covered Yarn (ACY) is ideal.
Sportswear & Activewear
- Typical Products: Athletic leggings, sports bras, compression wear, cycling shorts, and athletic tops.
- Key Yarn Features: 4-way stretch for unrestricted movement; excellent shape retention and recovery; moisture-wicking capabilities.
- Recommended Yarn Types: Double Covered Spandex Yarn (often with nylon or polyester sheath) for maximum performance and durability. The balanced structure is critical to prevent twisting during high-intensity activity.
Intimate Apparel & Swimwear
- Typical Products: Bras, underwear, shapewear, bikinis, and one-piece swimsuits.
- Key Yarn Features: Consistent, firm elasticity for support and control; chlorine resistance (swimwear); softness against the skin; resistance to body oils and lotions.
- Recommended Yarn Types: Double Covered Spandex Yarn is essential for opacity and fit. Nylon is a common sheath for both categories. Mechanical Covered Yarn (MCY) may be used in areas requiring high abrasion resistance.
Hosiery & Socks
- Typical Products: Pantyhose, tights, compression socks, and everyday socks.
- Key Yarn Features: Consistent gentle compression; ability to maintain fit and not sag; breathability.
- Recommended Yarn Types: Single Covered Spandex or Rubber Yarn, providing the necessary elasticity without excessive bulk. The softness of Air Covered Yarn (ACY) is highly desirable for comfort in this category.
Medical & Healthcare Textiles
- Typical Products: Surgical hosiery, compression bandages, orthopedic braces, and supportive garments.
- Key Yarn Features: Controlled, therapeutic pressure (graduated compression); biocompatibility and skin-friendliness; durability through repeated use and sterilization.
- Recommended Yarn Types: Double Covered Spandex Yarns for consistent performance, or covered rubber for higher power. The precision of Mechanical Covered Yarn (MCY) ensures consistent compression levels.
Seamless Garments
- Typical Products: Seamless leggings, underwear, and tops produced on circular knitting machines.
- Key Yarn Features: High uniformity and low torque to prevent garment spiraling; smooth surface to avoid snagging on knitting needles; excellent recovery.
- Recommended Yarn Types: Double Covered Spandex Yarn is predominantly used for its balanced structure and reliability in high-speed knitting. Air Covered Yarn (ACY) is also used where a loftier, softer hand is the priority.
Industrial and Technical Applications
- Typical Products: Elastic tapes and waistbands, technical upholstery, industrial belts, smart textiles, and geotextiles.
- Key Yarn Features: Exceptional durability and resistance to abrasion, UV light, and harsh environmental conditions; consistent elasticity under sustained load; ability to be integrated with conductive fibers.
- Recommended Yarn Types: Mechanical Covered Yarn (MCY) is the standard here, prized for its compact structure, high strength, and resistance to wear. Spandex or rubber cores are selected based on the required elasticity and environmental resilience.
Conclusion
Covered yarn is an indispensable component in modern textile manufacturing, enabling the creation of dynamic, comfortable, and high-performance fabrics. The diversity in its types—from core material and structure to production technology—allows for precise customization to meet the demanding requirements of virtually any application.
Choosing the right covered yarn is a strategic decision that impacts product quality, performance, and market success. By aligning the yarn’s properties with the end-use application, manufacturers can unlock new possibilities in design, comfort, and functionality.
Ready to integrate high-performance covered yarns into your next collection? Contact our specialists today for technical consultation and access to our extensive range of covered yarn solutions tailored to your specific needs.
TANI THREAD CO., LTD
- Address: Thanh Hoa Hamlet, Thanh Dien Commune, Chau Thanh District, Tay Ninh Province, Vietnam
- Hotline: 0984.841.239
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