Assessing Seam Integrity in Sports Jerseys after Multiple Laundering Cycles: Effect of Knit Structure, Abrasion, and Pilling.

Abstract

Seam durability is a critical factor in sports-jersey performance, as these garments undergo repeated laundering and mechanical stress. This study examined the relationship between pre-wash surface durability and post-wash seam integrity in four polyester knit fabrics commonly used in jerseys: eyelet, pin-dot mesh, jacquard, and interlock. Samples were sewn under standardized conditions and subjected to ten ISO 6330 laundering cycles (40°C, mild detergent, 30 min). Seam appearance was graded as excellent, good, or poor after the 3rd, 7th, and 10th washes. Pre-wash testing showed that eyelet combined low abrasion loss (0.005–0.006 mg) with maximum pilling resistance (5/5), while interlock had the lowest abrasion loss (0.002 mg) but weaker pilling (4/4). Pin-dot mesh and jacquard exhibited intermediate abrasion losses and high pilling resistance (5/5). After laundering, pin-dot mesh and jacquard retained the highest seam quality (final average = 2.73), eyelet showed moderate decline (2.60), and interlock deteriorated most severely (2.08). Statistical analysis confirmed significant differences at cycles 3 and 10 (p < 0.05), with seam performance at wash 7 strongly predicting outcomes at wash 10 (r = 0.674, p < 0.001). Findings suggest that pilling resistance is a stronger predictor of seam stability than abrasion loss. Pin-dot mesh and jacquard demonstrated the best durability, providing useful screening criteria for material selection in sportswear design.