Corduroy is a woven fabric with vertical ridges. With its iconic ribbed texture, corduroy exudes a sense of luxury and vintage charm. It’s widely used in the garment and home furnishing industry.
In this article, we will dive deep into the craftsmanship, classifications, and features of corduroy.
Material used in Corduroy
It’s usually made from cotton or a blend of cotton and other fibers. It can also be made with woven with blends of polyester and cotton or even full polyester. Different materials can create different visual effects and significantly influence the performance of corduroy. For example, the ridges present on wool corduroy are not as visible as the ridges on corduroy made with other materials.
How Corduroy is Made
Corduroy’s iconic texture is created through a multi-step process, which includes weaving, gluing, cutting, and finishing.
- Weaving: Most corduroy fabrics are woven in a plain weave pattern. Once the primary weave is complete, a pile yarn will be added to form the characteristic ridges, or wales, across the fabric. The pile yarn can be woven in V-shaped or W-shaped. The pile shape will affect the cost and performance of the fabric.
- Gluing: Glue is applied to the back of the woven fabric to ensure that the pile yarn does not pull through during the cutting process.
- Cutting and brushing: An industrial cutter sever the pile yarn. This yarn is then brushed to soften the ridges and remove excess fibers, creating a smoother finsih.
- Dyeing: The corduroy fabric will be pigment-dyed. The pattern created by this dyeing process will become more accentuated when being washed, which provides one of the most iconic visual appeals of the corduroy fabric.
Source: Corduroy – YouTube
Types of Corduroy Fabric Based on Wale Count
Corduroy can be sorted by its wale count, which is the number of the ridges or cords per inch on the fabric. Overall, the higher the wale count is, the finer and denser the corduroy texture appears; conversely, a lower wale count results in a rougher and looser texture. This count can vary from very fine to wide, and it determines the overall look and feel of the corduroy fabric.
- Standard Corduroy: Standard corduroy fabric has 11 wales per inch. However, any corduroy fabric with 8-13 wales per inch is usually considered to be standard corduroy. It strikes a balance between durability and flexibility, making it suitable for both clothing and upholstery.
- Elephant Corduroy: This corduroy is named for its resemblance to the wrinkles of elephant skin. It has very large, thick cords and can have a wale number between 1.5 and 6. Its bold texture can make a strong visual statement.
- Pinwale Corduroy: Pinwale corduroy features a large number of tiny ridges in every square inch and can feature up to 21 wales per inch. It’s softer and more flexible.
Features of Corduroy Fabric
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Durability: One of the unique feature of corduroy is its durability. Thanks to its thick weave, corduroy can withstand wear and tear.
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Warmth: Due to its raised parallel ridges, corduroy retains heat more effectively. This makes it a great material for keeping warm.
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Stylish: Corduroy has a natural sense of luxury and nostalgia, giving it a unique place in both the furniture and fashion industries. Additionally, with a wide range of colors and patterns available, corduroy can fit into different design styles, from classic to modern.
Conclusion
Corduroy is a durable fabric with a unique ribbed texture. It keeps heat well and stands up to wear and tear. With various colors and patterns available, it fits different styles. These features make corduroy a great choice for furniture, especially sofas.
As the weather gets colder, corduroy sofas are becoming more popular. Their warm feel and cozy look make them ideal for a comfortable home in colder seasons. Whether you’re a homeowner looking for a sofa or a retailer seeking a hot product, learning about corduroy sofas now is a smart move. If you are interested, please stay tuned for our upcoming industry report on corduroy sofas!
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