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Thermo-physiological properties of textiles are crucial in determining the heat and moisture transport from skin to environment and in the assessment of overall wearer comfort. Engineering fabrics with desirable thermo-physiological properties suited for specific applications such as active wear, intimate wear is a big challenge for textile manufacturers as gamut of fibre, yarn and fabric parameters are known to influence the thermo-physiological properties. The present study was undertaken with an aim to explore suitable combination of fibre and yarn variables for engineering polyester–cotton plated fabrics with good thermo-physiological properties. Categorical variables i.e. outer layer yarn type and inner layer fibre linear density were found to affect the thermal, moisture vapour and liquid moisture transfer properties of developed test samples. Fabrics knitted with carded yarn and polyester fibre of high linear density showed high thermal resistance and would feel warmer on initial skin contact owing to low thermal absorptivity. However, the air permeability and moisture vapour transmission rate increased with combination of combed cotton yarn in the outer and coarse polyester fibre in the inner layer. Combed yarn fabrics were superior in trans planar wicking compared to carded yarn fabrics which showed higher water absorbency and would be slow drying fabrics.

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