Burnout Fabric

Burnout fabric is a material that has been partially "burned out" to create a transparent or semi-transparent effect, often used in custom apparel for a unique look. The process involves applying a chemical paste that dissolves one fibre (usually cotton), leaving the synthetic fibre intact. The result is a lightweight fabric with distinctive sheer areas and a soft, textured appearance.

In the custom garment printing industry, burnout fabric is mainly used for fashion-forward apparel rather than heavy-duty workwear, offering a unique visual style and breathable comfort.

How Burnout Fabric Is Made

Fibre Blends and Chemical Process

Burnout fabric starts with a blended textile, most commonly cotton and polyester. A chemical solution is applied to specific areas of the fabric to break down the natural fibres while preserving the synthetic ones. After washing and finishing, the treated sections become semi-transparent, creating contrast between solid and sheer areas.

This process allows intricate patterns to be embedded directly into the fabric structure, rather than printed on the surface.

Key Features of Burnout Fabric

Lightweight and Breathable Feel

Because part of the fabric is removed, burnout fabric is extremely lightweight and breathable. This makes it suitable for warmer climates and casual wear, particularly in Australia’s spring and summer seasons.

Soft Texture and Draping

Burnout garments often have a soft, fluid drape that sits comfortably on the body. The fabric feels worn-in and relaxed, which appeals to lifestyle and fashion-focused markets.

Distinctive Visual Appeal

The combination of opaque and sheer areas gives burnout fabric a textured, layered look that stands out without heavy decoration.

Benefits of Burnout Fabric in Custom Apparel

Burnout fabric offers several advantages:

Unique aesthetic that does not rely on heavy printing
Enhanced breathability for warm-weather wear
Soft hand feel for all-day comfort
Fashion-forward appearance suitable for retail collections

For Australian brands seeking differentiation in competitive fashion markets, burnout fabric adds built-in visual interest.

Printing and Decoration Considerations

Suitable Printing Methods

Due to its lightweight and semi-transparent nature, burnout fabric requires careful decoration. Water-based screen printing and lightweight DTG printing are commonly used. Heavy ink coverage is generally avoided as it can stiffen the fabric and reduce breathability.

Artwork and Colour Selection

Simple designs with high contrast work best. Sheer sections of burnout fabric can affect colour appearance, so test prints are recommended to ensure visibility and consistency.

Common Use Cases in Australia

Burnout fabric is commonly used for:

Fashion t-shirts and tops
Boutique and lifestyle brand collections
Event merchandise with a premium feel
Casual promotional apparel

It is less suitable for uniforms, workwear, or garments requiring high durability.

Practical Insights and Suitability

Burnout fabric is best suited for light-duty, casual wear. It is not recommended for environments requiring frequent washing, abrasion resistance, or strict branding consistency. Care instructions often advise gentle washing and air drying to maintain fabric integrity.

Why Burnout Fabric Is a Niche but Valuable Option

Burnout fabric offers a distinctive blend of comfort, texture, and style. While it requires thoughtful design and printing choices, it provides Australian brands with an opportunity to create standout garments that feel lightweight, modern, and intentionally different. For the right application, burnout fabric delivers visual impact without relying on heavy decoration.