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The essential properties of active sports fabrics are moisture management, quick-drying, body heat management and thermal regulations. Fibre type, blending nature, yarn and fabric structure and the finishing treatment are the key parameters that influenced the performance of the clothing meant for sportswear. This study aims to investigate the effect of fibre blending and structural tightness factors on bi-layer sport fabric's dimensional, moisture management and thermal properties.

In this study, 12 different bi-layer inter-lock fabrics were produced. Polyester filament (120 Denier) yarn was fed to form the backside of the fabric, and the face side was varied with cotton, modal, wool and soya spun yarns of 30sNe. Three different types of structural tightness factors were considered, such as low, medium and high were taken for sample development. The assessment towards dimensional, moisture management and thermal properties was carried out on all the samples.

The polyester-modal blend with a high tightness factor has shown maximum overall moisture management capability (OMMC) values of 0.73 and air permeability of 205.3 cm³/cm²/s. The same sample has shown comparatively higher thermal conductivity of 61.72 × 10^–3 W m^-1 °C^-1(Under compression state) and 58.45 × 10^–3 W m^-1 °C^-1 (under recovery state). In the case of surface roughness is concerned, polyester-modal blends have shown the lowest surface roughness, surface roughness amplitude and surface friction co-efficient. Among the selected fibre combinations, the overall comfort level of polyester-modal bi-layer knitted structure with a higher tightness factor is appreciable. Polyester-modal is more suitable for active sportswear among the four fiber blend combinations.

The outcome of this study will help to gain a better understanding of fibre blends, structural tightness factor and other process specifications for the development of bi-layer fabric for active sportswear applications. The dynamic functional testing methods (Moisture management and Thermal properties) were carried out to simulate the actual wearing environment of the sports clothing. This study will create a new scope of research opportunities in the field of bi-layer sports textiles.

This study was conducted to explore the influence of fibre blend and structural tightness factor on the comfort level of sportswear and to find the suitable fibre blend for active sportswear clothing.