Flannel is a soft woven fabric made from cotton, wool, or synthetic fibers that has a slightly napped surface. It is a popular fabric choice for shirts, pajamas, robes, and other clothing because of its soft, warm, and comfortable feel against the skin. But not all flannels are created equal when it comes to softness. The softest flannels are made from high quality fibers, have a high thread count, and go through special finishing processes to maximize the fluffiness and coziness of the fabric.
What Makes Flannel Soft
There are a few key factors that determine how soft a flannel will be:
- Fiber content – Flannel made from fine cotton, wool, or microfiber will be softer than flannel made from coarse, low quality fibers.
- Thread count – Flannel with a high thread count (number of threads per square inch) feels softer and more supple.
- Napping – Brushing and napping the fabric raises fibrous nap, making flannel softer.
- Finishing – Softening finishes like sanforization helps maximize the fluffiness of the fabric.
The Softest Flannel Fibers
The fiber content has a big impact on the softness of flannel. Here are some of the best fiber options for soft flannel:
Cotton
High quality cotton flannel made from extra long staple cotton fibers is very soft and breathable. Pima cotton and Egyptian cotton are considered the highest grades of cotton and make exceptionally soft flannel.
Wool
Wool flannel has natural softness and insulation that gets even better with wear. Extra fine Merino wool makes some of the softest and most luxurious flannel.
Microfiber
Synthetic microfibers like polyester and nylon can be made into very soft flannel. Microfiber flannel has excellent heat retention too.
Flannel Fiber Comparison
| Fiber | Softness | Heat Retention | Breathability |
|---|---|---|---|
| Cotton | Very soft | Good | Excellent |
| Wool | Soft | Excellent | Good |
| Microfiber | Soft | Excellent | Moderate |
Optimizing Softness in Manufacturing
It’s not just the fiber type that determines the softness of the final flannel fabric. Manufacturing processes also play a key role:
- A high thread count per inch creates a tighter weave and softer feel.
- Napping or brushing the surface fibers raises a soft nap.
- Sanforization slightly shrinks and thickens fabric to make it feel lush.
- Softening washes reduce stiffness and enhance drape.
- Quality control checks ensure consistency and remove flaws.
Reputable brands pay close attention to optimizing these processes to create the softest and highest quality flannel.
The Softest Flannel Brands
When searching for the softest flannel shirts or sheets, these brands consistently rise to the top:
L.L. Bean
Known for their exceptionally soft cotton flannel shirts made from Portugal cotton. Their flannel bed sheets are also top rated for softness and durability after many washes.
Lands’ End
Offers high quality cotton flannel in a range of styles. Their lesson brushed flannel has an extra napping process for maximum softness.
Eddie Bauer
A go-to brand for soft, warm flannel in both casual and rugged styles. They use premium cotton fabrics and excellent stitching.
Duluth Trading Co.
Provides sturdy yet soft cotton flannel shirts for men and women. Known for durability and lived-in comfort.
Pendleton
Specializes in premium wool flannel, including ultra-soft virginal wool options. Excellent quality and craftsmanship.
Patagonia
Uses organic cotton and fleecy-soft double-napped flannel made through environmentally responsible processes.
Carhartt
Rugged, durable flannel shirts and jackets with a soft brushed interior. Quality garment washed flannel.
Polo Ralph Lauren
Timeless all-cotton flannel in both classic and modern fits. Softer feel after washing.
Tips for Buying the Softest Flannel
When evaluating flannel for softness, keep these tips in mind:
- Read fabric details to look for 100% cotton, wool, or microfiber content.
- See if the flannel is sanforized or garment washed for softness.
- Check item descriptions for terms like “brushed” or “napped” which increase softness.
- Read reviews to hear first-hand how soft the fabric feels for real customers.
- Compare thread count – typically over 150 threads per inch.
- Touch test the fabric when possible to judge softness and warmth.
With some research, you can find flannel that is super snuggly and soft to the touch. The highest quality flannel will maintain that luxurious feel even after many washes, becoming softer over time.
Caring for Soft Flannel
To keep flannel feeling its softest, follow these care tips:
- Wash in cold water on a gentle cycle.
- Use a mild detergent without harsh chemicals.
- Lay flat or hang to dry to avoid damage from heat.
- Iron on low heat if needed.
- Avoid bleach and fabric softeners which can break down fibers.
- Wash similar colors together to prevent fading.
With proper care, your high quality flannel can stay soft and cozy for many seasons of wear. It only gets better with time.
Conclusion
The softest flannel starts with premium natural fibers like cotton, wool, and microfiber. But the manufacturing processes like napping, sanforization, and wash treatments are also key to maximizing the softness of the finished fabric. When shopping for flannel, look for trusted brands that use quality materials and employ softening techniques. With some diligence, you can find flannel shirts, sheets, and other products that feel luxuriously soft and snuggly.