Sourcing American-Made: The Ultimate Guide to Thermal Knit Fabrics

As colder seasons approach, the demand for textured, insulating layers skyrockets. For clothing brands committed to domestic production, sourcing the perfect thermal knit fabric is often the biggest hurdle. Whether you are designing heavy-duty winter wear or cozy loungewear staples, the fabric foundation is everything.

At Greene Textile, we specialize in knitting premium thermal fabrics right here in Los Angeles, California. By keeping production local, we ensure top-tier quality control and faster turnaround times for brands that value "Made in the USA" integrity.

Here is a breakdown of the essential thermal varieties we manufacture, ranging from classic 100% cotton to sustainable organic options.

Greene Textile's Style 3904 thermal features a finely dyed organic cotton blend in French terry and rib, emphasizing its soft texture and eco-friendly craftsmanship.

The Classic: 100% Cotton Thermals

Nothing beats the breathability and hand-feel of pure cotton. It is the industry standard for a reason—soft against the skin, absorbent, and hypoallergenic. Our 100% cotton thermals utilize a "waffle" or honeycomb stitch that traps body heat while allowing air to circulate, preventing overheating.

Top Picks from Our Library:

• Style #4010 (Small Box Thermal): A versatile 10 oz fabric perfect for layering pieces. Its tighter gauge offers a refined look suitable for contemporary fashion.

• Style #3904 (Large Box Thermal): A slightly heavier 10-11 oz option with a more pronounced texture. This is the quintessential "long john" fabric, providing that rugged, vintage aesthetic.

• Style #4034 (100% Cotton Waffle): At 11-11.5 oz, this robust waffle knit is ideal for robes, heavy henleys, and textured cardigans.

Performance Meets Comfort: Cotton Spandex Blends

While 100% cotton is timeless, modern silhouettes often require a bit more movement. Adding a touch of Spandex (Elastane) to the knit construction transforms a standard thermal into a performance fabric.

A Cotton Spandex Thermal offers superior recovery. This means elbows and knees won’t "bag out" after a day of wear. It creates a form-fitting garment that moves with the body, making it an excellent choice for fitted tops, leggings, and active-lifestyle collections.

The Sustainable Choice: Organic Cotton & Organic Cotton Spandex

Sustainability is no longer a niche market; it is a necessity. For brands focusing on eco-conscious consumers, we offer the ability to knit our popular thermal styles using Certified Organic Cotton.

• 100% Organic Cotton Thermal: All the texture and warmth of our standard styles, but grown without toxic pesticides or synthetic fertilizers.

• Organic Cotton Spandex Thermal: The ultimate hybrid of eco-responsibility and modern comfort. You get the clean supply chain of organic fiber with the necessary stretch for high-end garment construction.

Note: As a custom knitting house, we can transition many of our standard styles into organic versions upon request.

A Note on Poly Cotton

While our primary focus is on natural fibers, we understand that certain price points or durability requirements call for blends. We do offer options like Style #4031 (Poly Cotton Waffle), which blends the softness of cotton with the durability and color retention of polyester. It’s a reliable workhorse fabric for uniforms or high-abrasion environments.

Why Knit in the USA?

Sourcing from Greene Textile means your fabric is knitting, dyeing, and finishing in Los Angeles. We eliminate the uncertainty of overseas supply chains. Whether you need a low-minimum stock roll of PFD (Prepared for Dye) Small Box Thermal or a custom production run of Heavy Honeycomb Thermal (Style #4128), we are your local partner in production.

Ready to start your next collection? Visit www.greenetextile.com/thermals to view our full library of thermal and waffle knits.