Polyester is a manufactured product made from synthesized polymers. It tends to be very resilient, quick drying, resistant to biological damage such as mold and mildew, easy to wash, and able to hold forms well. While polyester is often maligned as a textile, it has many useful applications. Polyester is, however, highly flammable, so care should be taken when wearing it. Most synthetic fabrics are subject to flammability by nature, because they are made from polymers.

Polyester is not just a textile. It is made from polyethylene terephthalate (PET), the same material used to make plastic drink bottles. Many drink bottles are recycled by being reheated and turned into polyester fibers, which in addition to being an efficient use, also helps keep polymers out of landfills. Polyester is a plastic, invented in Britain in the early 1940s by two gentlemen working with synthetic polymers. In the 1950s, the new textile took off, becoming popular for its easy care, drape, and versatility.

In the United States, Dupont is one of the major manufacturers of PET and has been making Dacron polyester since 1950. Dupont has researched the properties of polyester extensively and devised a number of uses well beyond textiles, such as mylar and other polyester films. Dupont has also been driven to find ways to recycle polyester products to help keep costs down, as the base chemical substances that combine to form polyester are petroleum products.

To make polyester, ethylene glycol and dimethyl terephthalate are mixed together. The chemical reaction results in bisterephthalate. This substance is heated to 270° Fahrenheit (132° Celsius), where it reacts again to form polyethylene terephthalate. Like many chemical reactions that result in polymers, the polyester making process results in unhealthy off gassing, and protection should be worn while making PET. After synthesizing the polymers, the manufacturer decides what to do with them.

PET can be formed into plastics that can later be recycled. It is a highly malleable material and appears in all sorts of applications, from drink bottles to floppy disk liners. PET can also be used to make polyester fiber, which is used in auto upholstery, quilt batting, and clothing of all sorts.

To make polyester fiber, an extruder is used to produce very fine threads of PET. Polyester clothing tends to be slippery and silky in feel, although it can cause skin irritation for some wearers. The polyester fibers used to make clothing can be knitted or woven, although most are knit, to maximize the flexibility of polyester. Some polyester is blended with other fabrics to provide more loft or stretch, or to minimize skin irritation.