The Hidden Plastics in Our Clothes

Bottles, straws, and shopping bags are what come to mind when we think of plastic, not the clothes we wear every day. Yet, much of our fashion is built from synthetic fibres like polyester, nylon, and acrylic. Think about your soft workout top, or even your favourite leggings, they are made from plastic.

These fabrics have made fashion cheaper, stretchier, and more accessible, but they come with a hidden cost: they shed tiny microfibres when washed, and these linger in the environment long after we’ve stopped wearing them.

Synthetic fibres aren’t inherently bad. As we will find in this article, they’ve shaped modern fashion as we know it. Originally designed to mimic natural fibres, they became the backbone of modern production because they are light, durable, and cheap to manufacture. Today, around 59% of global clothing is made from synthetics, but mainly for profitability, fueling a system of overproduction, waste, and disposability.

While they made fashion more accessible, they also introduced hidden costs that the planet is now paying for.

What are Synthetic Fibres?

Synthetic fabrics are textiles created through industrial processes that transform petroleum-based chemicals into fibres, such as polyester, nylon, acrylic, etc.

• Polyester: Polyester is made from petroleum-based polymers. It makes up more than half of all fibres produced worldwide. It is loved for being cheap, strong, and wrinkle-resistant.
• Nylon: First introduced as a replacement for silk, nylon brought us stockings, swimwear, and underwear. It’s stretchy, durable, and smooth.
• Acrylic: Often used as a wool substitute, acrylic is lightweight and soft but less durable, which makes it common in low-cost sweaters and knitwear.

The Hidden Cost of Synthetic Fibres

Synthetic fabrics create environmental damage long before we eventually wear them. Their production is energy-intensive, chemically polluting, and entirely dependent on fossil fuels.

Polyester alone accounts for over half of global fibre production and emits more than 700 million tons of CO₂ annually.

Manufacturing also relies on toxic chemicals like azo dyes (linked to carcinogenic risks), formaldehyde (used in wrinkle resistance, irritating to skin and lungs), and per- and polyfluoroalkyl substances (PFAS) for waterproofing (also known as “forever chemicals” because they don’t break down in the environment).

In manufacturing hubs like China, Bangladesh, and India, untreated factory runoff has also been found to contain heavy metals such as chromium, lead, and cadmium, which contaminate rivers and threaten ecosystems and communities.

Producing synthetic fibres requires extremely high heat, often powered by coal plants, alongside significant water use, driving up carbon emissions, water pollution, and resource depletion.

Post-production, every wash cycle releases microfibres that slip through wastewater systems and end up in rivers, oceans, and even our food and drinking water. In fact, synthetic textiles are responsible for about 35% of the microplastics in the ocean. Unlike natural fibres, which decompose quickly, synthetics can persist for centuries, making the environmental cost of cheap clothing far higher than its price tag suggests.

Alternatives to Synthetic Fibres

While synthetic fabrics have dominated the global textile market, they aren’t the only option. As concerns about waste, pollution, and fossil fuel dependency rise, the fashion industry is exploring alternatives, both innovative synthetics and traditional natural fibres, that can reduce environmental impact.

For applications where synthetics remain necessary, innovation is driving progress. These newer materials don’t erase every environmental concern, but they do mark an important shift toward lower-impact options.

For example, bio-based nylon made from plant-based materials, such as corn or sugarcane. It offers the same strength and durability as conventional nylon but is designed to be biodegradable.

Polylactic Acid (PLA) is produced from resources such as corn starch. It is similar to polyester, but it’s biodegradable, making it a promising substitute for single-use or short-life textiles.

There’s also rayon, which is created from regenerated cellulose sourced from wood pulp. It possesses the breathable and absorbent qualities of natural fibres, while its partial biodegradability distinguishes it from fully synthetic fabrics.

Synthetic fibres are cheaper, stretchier, and easier to produce at scale, but what they offer in affordability, they lack in sustainability. Natural fibres, on the other hand, bring qualities that synthetics can only imitate, such as breathability, comfort, and biodegradability.

Cotton, for example, can break down in as little as three months under the right conditions, while polyester can take over 200 years. They may cost more upfront, but they reduce long-term environmental harm while offering durability and wearability that outlasts fast-fashion synthetics.

Different kinds of textile materials | Moonstarious Project on Unsplash.

Natural Fibres

Natural fibres come from renewable sources that break down at the end of their life cycle. Cotton, wool, and silk have been used for centuries, proving that fashion can thrive without being tethered to petroleum.

• Cotton: Soft, breathable, and durable, cotton remains one of the world’s most versatile fibres. While conventional farming can be resource-heavy, the rise of organic, recycled, and regenerative cotton shows how innovation can make this age-old fabric far more sustainable.
• Wool: Naturally insulating and long-lasting, wool is biodegradable and renewable, offering a fibre that resists disposability.
• Silk: Luxurious yet practical, silk regulates temperature and is hypoallergenic, all while being renewable and biodegradable.

Natural fibres aren’t without challenges; cotton farming can demand high water use, and wool and silk raise questions about animal welfare. But these impacts can be reduced through organic and regenerative agriculture, recycled fibres, and ethical sourcing. With thoughtful choices and innovation, natural fibres point us toward a wardrobe that works with, not against, the planet.

Synthetic fibres may have made fashion cheaper and more accessible, but their hidden costs are clear. The good news is we’re not stuck with this system. Natural fibres remind us that clothing doesn’t have to come at the planet’s expense, while innovators are proving that comfort and performance can exist without a plastic footprint. Brands like Nigerian label This is Us work with local cotton and artisans, and global players like Pangaia are experimenting with bio-based synthetics. These shifts show that fashion can be both creative and responsible.

The future of fashion isn’t about abandoning style for sustainability, it’s about recognising the hidden plastics in our wardrobes and choosing fibres that don’t cost the earth.