Shop flannel fabric by the yard - soft, brushed woven fabric perfect for cozy fall and winter projects. Features a fuzzy texture on one or both sides for exceptional warmth and comfort. Ideal for pajamas, blankets, scarves, and cold-weather apparel.
Uses: pajamas, fall/winter apparel, blankets, scarves, etc.
Care: Wash cold, tumble dry low. Always pre-wash and dry.
Stretch: None
Fabric Content: 100% Cotton.
Flannel fabric is the ultimate cold-weather companion - soft, warm, and endlessly cozy. With its distinctive brushed surface and fuzzy texture, flannel has been keeping people comfortable for centuries. Whether you're sewing classic plaid pajamas, wrapping up in a warm blanket, or creating adorable baby items, flannel delivers unmatched softness and warmth.
From traditional buffalo plaid to modern prints featuring animals, outer space, and novelty designs, flannel offers endless creative possibilities. The fabric's loose weave and brushed fibers trap heat while remaining breathable - making it perfect for layering through fall and winter!
Flannel is a woven fabric made from loosely spun yarns or fine fibers that create a soft, fuzzy texture on one or both sides through a brushing process called napping. Most flannel is made from 100% cotton, though it can also be made from wool or synthetic fibers. The fabric features either a plain weave or twill weave construction, which is often hidden by the brushed surface.
What makes flannel special is the napping process - after the fabric is woven, it's brushed to pull the fibers to the surface, creating that signature fuzzy, soft texture we all love. This brushed surface is what gives flannel its exceptional warmth and cozy feel. The loose weave combined with the raised fibers creates air pockets that trap heat while still allowing airflow, making flannel warm without being stuffy.
Flannel is believed to have Welsh origins dating back centuries. The Welsh natives would have greatly benefited from flannel's warmth given their cool, damp climate. Their process of creating flannel included using leftover sheep wool that was separated through carding, spun into worsted yarn, woven into fabric, brushed to create the fluffy texture, and then dyed.
The plaid design we commonly associate with flannel can trace its roots back to Celtic traditions before the 10th century, although plaid is just a pattern design rather than being inherent to flannel itself. Today, Asia and Australia are the biggest producers of flannel fabric.
Flannel was also used during times of war in the United States to help keep soldiers warm and comfortable in harsh conditions. It eventually made its way into everyday wear when construction workers, lumberjacks, and railroad workers began wearing flannel shirts for their durability and warmth during long days of outdoor labor. In present day, flannel has become both a practical cold-weather fabric and a fashion statement, with classic plaid flannel shirts being a wardrobe staple for people of all ages.
Made from 100% cotton and napped on both sides, making it exceptionally soft and breathable. This is the most popular type of flannel and what we carry at KnitFabric.com. Perfect for bedding sheets, pajamas, blankets, baby items, and cold-weather apparel. Cotton flannel is machine washable, gets softer with each wash, and is gentle enough for sensitive skin.
Made from wool fibers, this type of flannel is naturally flame-resistant and provides excellent insulation. Wool flannel is commonly found and used in European countries. It's heavier than cotton flannel and perfect for outerwear, blazers, and structured garments. Requires more careful washing (typically hand wash or dry clean only).
Made from polyester or blended fibers, synthetic flannel is often treated with flame retardants. While it can be more affordable, synthetic flannel is harsher on the environment and typically doesn't breathe as well as natural fibers. It may not soften with washing like cotton flannel does.
Flannel is made with either a twill weave or plain weave, which is typically hidden to the naked eye due to the napping and brushing process. The weave quality matters significantly for durability:
Checking Weave Tightness: Hold the fabric up to the light. A tighter weave (less light coming through) will hold up better than a looser weave. Looser weaves are more prone to stretching, shrinking, and wear over time. Higher quality flannel has a tighter weave with more substantial brushed fibers.
Yes, absolutely! Pre-washing flannel is essential. Flannel can shrink significantly on the first wash - some flannels can shrink up to 10-20% if not pre-washed. Always wash in cold water with mild detergent, then dry on a heat cycle to get all the shrinking out of the way before cutting and sewing. This also helps remove any manufacturer's sizing or chemicals. After pre-washing, iron your flannel before cutting to ensure accurate measurements and clean cuts.
Flannel's softness comes from the brushing (napping) process that pulls fibers to the surface, creating a fuzzy texture. Its warmth comes from the combination of the loose weave and raised fibers, which create air pockets that trap body heat while still allowing airflow. The fabric's moisture-wicking properties and larger air pockets prevent it from feeling stuffy or sweaty, making it warm without being uncomfortable. Plus, flannel gets softer with every wash as the fibers continue to relax and soften!
No, flannel is a woven fabric with no stretch. Like other wovens, it only has a slight bias stretch when pulled diagonally. This means you should choose sewing patterns designed for woven fabrics, not patterns designed for knits. The lack of stretch helps flannel maintain its shape and structure, making it perfect for pajama pants, shirts, and blankets that need to hold their form.
Flannel has a loose weave which makes it more prone to fraying than tighter woven fabrics. Always finish your seam allowances - you can use a serger/overlock, zigzag stitch on your sewing machine, or pinking shears to finish edges. Also avoid seam ripping if possible, as this can create unwanted holes and additional fraying in the fabric. When cutting flannel, use sharp scissors or a rotary cutter for clean edges that will fray less.
Use a universal needle in size 80/12 or 90/14 for most flannel projects. The slightly larger needle helps penetrate the looser weave without snagging the brushed fibers. Always start with a fresh, sharp needle - dull needles can snag the fuzzy surface and create skipped stitches. For heavier flannel or multiple layers (like quilts), you may want to size up to a 90/14 or even 100/16 needle.
Plaid and other directional prints (like stripes or one-way designs) require pattern matching to look professional. This means you need to carefully position pattern pieces so the plaid lines match at seams. This strategic placement often results in more fabric waste, so you'll need to purchase extra yardage - typically 1/4 to 1/2 yard more than the pattern calls for. It's always a good rule of thumb to purchase extra flannel anyway to account for shrinkage and potential mishaps.
While flannel is most popular for fall and winter due to its warmth, it can actually be used year-round depending on the project and climate. Cotton flannel sheets are breathable enough for some people to use all year. Lightweight flannel can work for spring/fall transitional clothing. However, for hot summer weather, lighter fabrics like cotton lawn, double gauze, or poplin are more comfortable choices. The brushed surface and insulating properties of flannel make it best suited for cooler temperatures.
Wash flannel in cold or warm water with mild detergent. Avoid harsh soaps which may cause fading, especially with darker colors like red and black. Dry on low to medium heat, or line dry to minimize shrinkage. Remove items promptly from the dryer to prevent deep wrinkles. You can iron flannel on a medium to high heat setting if needed. Flannel actually gets softer with each wash as the fibers relax and soften further, so your projects will become even cozier over time!
Quilting cotton is a plain weave cotton fabric with a smooth, crisp surface and no brushing. It's more structured and maintains its shape well, perfect for quilts, structured dresses, and items that need body. Flannel is brushed on one or both sides to create a soft, fuzzy surface. It's softer, warmer, and less structured than quilting cotton. Quilting cotton is versatile for year-round use while flannel is specifically perfect for cold-weather projects. Both are woven fabrics with no stretch.
Yes! Cotton flannel is excellent for baby items. It's soft and gentle on sensitive skin, breathable, warm without overheating, 100% natural cotton (hypoallergenic), and becomes softer with each wash. Flannel is perfect for receiving blankets, burp cloths, swaddles, crib sheets, and baby pajamas. Just be sure to pre-wash thoroughly to remove any sizing and complete shrinkage before sewing. The cozy softness makes flannel a favorite for both babies and parents!
Plaid flannel is the most iconic and timeless flannel pattern. We carry a wide variety of plaids including:
Perfect for coordinating with plaids and prints, or creating your own color story. Available in classic flannel colors including white, red, black, navy, hunter green, and pastels.
Minky is a knit fabric with a plush, velvety surface. It's stretchier and plusher than flannel, perfect for blankets and stuffed animals. Flannel is a woven with no stretch, making it better for structured items like pajamas and shirts.
Fleece is typically made from polyester and has no nap - it's a knit fabric. Fleece is warmer and more weather-resistant than flannel, perfect for outerwear. Flannel is 100% cotton, more breathable, and softer against skin.
Sweatshirt fleece is a knit fabric with smooth outside and fuzzy inside. It has stretch and is perfect for sweatshirts and loungewear. Flannel is a woven with no stretch, making it ideal for pajamas and structured garments.
French Terry is a knit fabric with loops on one side. It's year-round versatile with medium weight. Flannel is specifically for cold weather with its brushed, insulating surface.
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