Why is plastic-free stretch fabric still so hard to make?

Hi everyone,

I’m working on a project around *fully* plastic-free activewear (leggings, sports bras, cycling shorts — the usual suspects). The idea is to use only natural fibres + natural rubber and avoid anything synthetic: no polyester, no nylon, no elastane/spandex, and no bio-based synthetics either.

But as soon as you enter the world of “stretch,” the whole industry basically shrugs and says: “Yeah… good luck with that.”

Which makes me wonder: we can put people on the moon… but we still can’t make a natural version of Lycra? How is *that* the impossible part? 🌕😅

So I’d love to pick the hive mind’s brain:

- Why is it so difficult to create a *fully natural* elastic fibre suitable for high-performance activewear? Is it a pure materials-science limitation, or more of a funding / R&D priority problem?

- Are there any promising companies working on natural-rubber-based elastic yarns or other plastic-free stretch technologies? I’ve heard about a few players experimenting with natural rubber filaments, but info is super scattered.

- Has anyone tested these new natural or “natural-leaning” elastic yarns in real life? (Think: stretch/recovery after workouts, durability, washing, sweat, comfort, etc.)

- And if you work in textiles: what’s realistically holding back a natural alternative to elastane?

I’m not expecting miracles, but I want to understand the *real* bottlenecks before deciding whether to explore blended fabrics or keep pushing the 100% natural route.

Would love any insights, experiences, lab data, ranting, or even “don’t do it, save yourself” warnings.

Thanks in advance — and in case NASA is reading this, please add “natural stretch fibre” to your moon budget. 🚀

Submitted November 27, 2025 at 05:44AM by PhilosopherAble7692 https://ift.tt/e1hD8dI