In recent years, lightweight jackets have become increasingly popular in the apparel industry. Almost every major outdoor brand now offers a ‘weightless’ or ‘packable’ collection, and we often receive requests with strict weight ranges from our customers.

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The global lightweight jacket market is projected to grow from $141.81 billion in 2023 to $209.62 billion by 2030, with an annual growth rate of 5.7%​ (MarketResearch)​. This growth is driven by changing consumer lifestyles, technological advancements, and rising temperatures, increasing the demand for adaptable, lightweight clothing.

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Before discussing how to make a jacket lightweight, let's define what we mean by it. Lightweight jackets can include different styles, from nearly weightless running windbreakers to lightweight waterproof shells and packable winter puffer jackets. While each design uses different fabrics and finishes, they all share some common features that we'll explore in this article.

What is the Best Fabric for a Lightweight Jacket?

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While both polyester and nylon can be used to design lightweight jackets, nylon is usually preferred. Nylon yarn can be spun as thin as 20-30 deniers and even the finest 10 deniers in our new development, maintaining high tensile strength and tear resistance. The most straightforward rule is that the lower the denier of the yarn, the lighter the fabric. But the unfinished fabric is only half the process; the finishing is what truly makes a difference.

How Can I Make My Jacket Thinner?

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Coating vs Lamination

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Traditionally, outdoor brands would coat the fabric of lightweight jackets to achieve waterproof features while maintaining low weight. Yet, this approach has drawbacks, as the coating often fails to protect against heavy rain and can compromise breathability. With the latest advancements in lamination technology, fabrics with membranes can now weigh around 60 g/m², providing high water resistance and breathability.

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New Lamination Technologies

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1. Moving From Full to Ultra-Thin DOT Lamination

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Many brands are transitioning from full lamination to DOT lamination to reduce the weight of their membranes. DOT lamination applies the membrane in a pattern of small dots instead of a continuous layer. This method improves breathability and flexibility while maintaining waterproof properties. Full lamination adds about 50 g/m² to the fabric, in contrast, DOT lamination reduces the weight to around 35 g/m².  At FlyingTex, we apply ultra-lightweight membranes that push this innovation further, achieving weights as low as 30 g/m². These advancements ensure that the fabric remains light without sacrificing performance.

2. Eliminating the Third Layer With LiteShell Membrane

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Typically, laminated fabrics include a third tricot layer to enhance visual appeal and provide a soft touch against the skin, adding an extra 20 g/m² to the fabric weight. But not with our LiteShell membrane! The graphic print on the membrane side offers an attractive look when you unzip the jacket, and an invisible treatment gives a dry and cooling touch, eliminating the need for the third layer.

As winters get warmer and people change their lifestyles to always be on the go, the demand for lightweight jackets will keep increasing, meaning more brands face the need to transform their product lines. At FlyingTex, we are always one step ahead and can provide the lightest high-functional fabrics for all seasons and purposes. Contact us today to get your free samples at [email protected]!