Design and analysis of polyester/cotton sirofil yarn warp–knitted suit fabric

Purpose Warp-knitted suit fabrics have become a topic of interest in recent years because of the growing need for casual wear as a symbol of mainstream lifestyle. To design a comfortable warp-knitted fabric with adequate bending rigidity and elastic recovery for suits, two types of warp-knitted suit fabrics with polyester/cotton sirofil yarn (CVC) were developed. Design/methodology/approach Two types of CVC warp-knitted suit fabrics were designed and fabricated using 100D/30D 40s C/T sirofil yarn on a Karl Mayer HKS-3M high-speed warp-knitting machine, following a warp plain weave padding structure. The fabricated samples underwent a series of performance tests, including air permeability, moisture permeability, bending rigidity, crease recovery and pilling resistance. Based on the experimental results, a comprehensive evaluation model was established to assess the overall performance of the fabrics. The findings demonstrate that CVC warp-knitted suit fabrics exhibit superior comprehensive properties. An H-shaped silhouette warp-knitted suit was developed, balancing structural formality and enhanced comfort, validated by sensory evaluation to outperform woven suits due to the fabric’s superior bending resilience and elastic recovery. Findings It was found that CVC warp-knitted fabric had good thermal and humidity comfort, bending rigidity and dimensional stability. Based on the experimental results, a comprehensive evaluation model was established to assess the overall performance of the fabrics. The findings demonstrate that CVC warp-knitted suit fabrics exhibit superior comprehensive properties. An H-shaped silhouette warp-knitted suit was developed and validated by sensory evaluation to outperform woven suits due to the fabric’s superior bending resilience and elastic recovery. Research limitations/implications Additionally, the study focused primarily on mechanical and comfort properties, while other factors like long-term durability and environmental impact were not thoroughly investigated. To address these limitations, future research could explore a wider variety of yarn blends and fabric structures as well as incorporate advanced testing methods to evaluate long-term performance and sustainability. Practical implications The development of these fabrics not only enriches the diversity of suit materials but also provides innovative insights for the design and production of suit fabrics. Social implications This study addresses the growing demand for lightweight business attire that combines comfort and easy-care features, meeting the public’s increasing expectations for high-performance clothing. Originality/value Two types of warp-knitted CVC suit fabrics were developed, subjected to comprehensive performance tests and evaluated via the gray evaluation method. A warp-knitted suit was then fabricated, and its arm comfort was compared with traditional suits through sensory evaluation, concluding that the developed warp-knitted suit exhibits superior comfort.