· By newsort staff
Why a Good 100% Cotton Panty Is (Almost) Impossible to Make
Most people love the idea of 100% cotton underwear…
until they actually try it.
Because historically, cotton panties have meant one thing:
thick, bulky, baggy, slightly faded, aka granny panties.
That's because 100% cotton introduces a ton of engineering constraints (and why so few brands attempt fully cotton styles to begin with).
Here’s what makes it nearly impossible:
1. Cotton isn’t naturally stretchy
Think about a plant: plants don’t stretch.
Unlike synthetics, which can be engineered like a custom chemical recipe, cotton comes with fixed physical properties.
Cotton is incredible because:
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its loose fiber structure traps more air
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more air = better breathability and thermoregulation than synthetics
100% cotton doesn't stretch, but if you want something to be form-fitting, it needs to stretch. Classic catch 22.
2. Cotton shrinks (a lot)
Yes, even pre-shrunk cotton.
True 100% cotton can shrink 3–4× more in high-heat wash/dry cycles compared to blends.
Combine that with the lack of stretch…. it's not worth the risk to produce.
3. Cotton is naturally bulkier
Synthetic fibers can be extruded (literally like Play-Doh) into ultra-fine, ultra-strong threads.
Cotton cannot.
Cotton can only go so thin before it becomes weak and prone to breakage.
So most 100% cotton underwear not only looks thicker but *feels* thicker and less pliant on-body
The contrast feels dramatic if you’re used to nylon-spandex blends.
4. Cotton is fuzzy, matte, and fades faster
At a microscopic level, cotton has lots of tiny fiber ends sticking out.
Those fiber ends = fuzz
Fuzz = matte texture
Matte texture = less “clean,” “high-end,” or “sexy” compared to the slight sheen of synthetics.
Most people don’t consciously think about this, but they feel it.
Cotton also fades more quickly, which quickly gives it that "used, lived-in" look that's especially unflattering as underwear.
Kinda makes sense, right? The designers making cotton underwear weren’t sitting there trying to make granny panties, that was simply the best the materials allowed for.
Until now.
We obsessed over every constraint and worked the problem from the fiber level up. Not because we wanted to be clever, but because if we weren't willing to compromise between health and looking hot, other women wouldn't either. And we all deserve a better way.
The result?
A new sort of 100% cotton.