Performance Evaluation of Sustainable and Conventional Hybrid Yarns for Woven Fabrics

The growing demand for sustainable textiles has prompted consideration of bio‐based, biodegradable sources as replacements for conventional elastomeric filaments in the production of composite yarns. In this study, four types of yarns, sustainable and conventional single‐core and dual‐core spun yarns, were produced using a modified ring‐spinning system. Their effects on yarn and fabric properties were systematically investigated. Results showed that conventional yarns exhibited higher tensile strength, extensibility, and dimensional stability. However, sustainable yarns and their corresponding fabrics demonstrated comparable mechanical performance within acceptable limits. Specifically, fabric made from the conventional dual‐core yarn (H4) exhibited the highest tensile strength of 1010 N in warp and 373 N in weft, as well as the lowest growth of 5.6% among all samples. Fabric produced by using the sustainable dual‐core yarn (H3) showed a lower tensile strength, whereas the yarn showed a lower imperfection (IPI = 315) as well as better structural uniformity. Statistical analysis (MANOVA) proved that yarn structure significantly influenced various performance parameters ( p < 0.05). Additionally, TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) identified H4 as the best performing alternative across all samples. These findings, especially the higher strength and stability of H4 and the improved structural uniformity and reduced imperfections of H3, indicate that although conventional systems currently offer superior mechanical performance, sustainable alternatives based on bio‐based elastane and PLA provide reliable functionality while offering environmental benefits.