In the textile industry, core spun yarn and covered yarn are two distinct yet often confused types of yarn used in creating fabrics with specific performance qualities. While both involve a central core surrounded by other fibers, their construction, properties, and applications differ significantly. Understanding the difference between core spun and covered yarn is essential for textile manufacturers, fashion designers, and anyone sourcing materials for apparel or industrial fabrics.
Core Spun Yarn

Definition

Core spun yarn is a type of yarn in which a central core fiber is surrounded by a sheath of another fiber. This construction combines the best qualities of both fibers—offering the strength and performance of the core with the comfort and style of the sheath.

Construction

The manufacturing process involves feeding a continuous core filament (often spandex, polyester, or nylon) into a spinning frame, while staple fibers such as cotton, wool, or rayon are spun around it. The result is a tightly bonded yarn where the outer layer completely covers the core filament, providing a uniform appearance while retaining the inner strength and elasticity.

Properties

Elasticity / Stretch – The presence of spandex or other elastic core materials gives core spun yarn excellent stretch recovery, making fabrics comfortable and form-fitting.
Durability – The combination of a strong core and a protective outer sheath improves abrasion resistance and longevity.
Comfort – The sheath fiber determines the feel against the skin; cotton sheaths offer softness, while synthetic sheaths can add moisture-wicking or quick-dry capabilities.
Shape Retention – The elastic core helps garments keep their original shape after repeated wear and washing.

Applications

Core spun yarn is widely used in:

Stretch Denim – Adds flexibility without compromising the rugged look of jeans.
Sportswear & Activewear – Provides freedom of movement for athletic performance.
Undergarments – Enhances comfort and fit for lingerie and intimate apparel.
Workwear – Offers durability while allowing for ease of movement.
Sewing Threads – Produces strong, smooth stitches that withstand repeated stress.

Covered Yarn

Definition

Covered yarn is a type of yarn where a central core yarn is completely wrapped by one or more layers of another fiber. Unlike core spun yarn, where the sheath is created during the spinning process, covered yarn is produced by mechanically winding the covering fiber(s) around the core, which may be made from elastic materials like spandex or from non-elastic filaments such as polyester or nylon.

Construction

The covered yarn manufacturing process involves:

Single Covering – One layer of covering yarn is wound around the core.
Double Covering – Two layers of covering yarn are wound in opposite directions, creating a balanced and more stable structure.

This wrapping method protects the core and can be engineered to achieve specific characteristics such as high elasticity, heat resistance, or a decorative appearance.

Properties

Variety of Textures – The outer covering determines the yarn’s surface feel, from silky smooth to textured.
Increased Strength – The covering reinforces the core yarn, improving its tensile strength and wear resistance.
Customizable Performance – Depending on the fiber used for the core and covering, the yarn can be made to resist heat, repel moisture, or deliver high stretch.
Enhanced Appearance – The covering can be colored, patterned, or metallic for fashion and decorative purposes.

Applications

Covered yarn is widely used in:

Hosiery – For elasticity, durability, and smooth appearance in tights, stockings, and socks.
Industrial Fabrics – In conveyor belts, elastic bands, and technical textiles.
Sewing Threads – Where high strength and consistent tension are required.
Elastic Waistbands – Providing stretch and comfort in sportswear and casual clothing.
Swimwear & Dancewear – Offering high stretch and recovery with a smooth finish.

Key Differences Between Core Spun and Covered Yarn

While core spun yarn and covered yarn both feature a central core surrounded by other fibers, their construction methods, properties, and applications set them apart. Understanding these differences helps textile professionals choose the right yarn type for specific performance and aesthetic needs.

1. Construction

Core Spun Yarn – The sheath fiber is spun directly around the core fiber during the spinning process, 

integrating both into a single structure.
Covered Yarn – The core yarn is mechanically wrapped with one or more covering fibers after the core is formed. The wrapping can be single or double for added stability.

2. Elasticity

Core Spun Yarn – Typically offers higher elasticity, especially when the core is made from spandex.
Covered Yarn – Elasticity depends on the core fiber and the wrapping method; double covering may slightly reduce stretch but increase stability.

3. Durability

Core Spun Yarn – Offers good durability thanks to the combination of a strong core and protective sheath.
Covered Yarn – Generally more durable due to the extra protection from the wrapping layers, especially with double covering.

4. Texture and Appearance

Core Spun Yarn – Texture depends on the sheath fiber; often smooth and uniform.
Covered Yarn – Offers greater variety, as the covering fiber can be textured, patterned, or decorative.

5. Applications

Core Spun Yarn – Best for stretch fabrics, denim, sportswear, and garments requiring shape retention.
Covered Yarn – Ideal for hosiery, industrial fabrics, sewing threads, and elastic components like waistbands.

Comparison Table

Conclusion

Both core spun yarn and covered yarn play essential roles in the textile industry, each offering distinct advantages depending on the desired fabric performance, appearance, and end use.

Core spun yarn excels in applications where high elasticity, shape retention, and comfort are priorities—such as in stretch denim, sportswear, and fitted garments. Its integrated core-and-sheath construction delivers flexibility without sacrificing durability.

Covered yarn, on the other hand, is often chosen for projects requiring exceptional durability, specialized performance, or decorative finishes. With single or double covering options, it offers greater versatility in texture, appearance, and protective qualities, making it ideal for hosiery, sewing threads, and technical fabrics.

By understanding the difference between core spun and covered yarn, textile professionals can make informed decisions that ensure the final product meets performance goals, aesthetic preferences, and cost requirements. Whether you are creating high-performance sportswear, luxury hosiery, or industrial textiles, selecting the right yarn is the foundation for achieving quality and functionality.