Design + DIY

The Road to Flannel: Our Newest Pajama Fabric

We’re thrilled to introduce our best selling bagheera print in a new fabric - flannel. Learn all about our journey to releasing a new fabric this week on the PF Mag. 
By Printfresh Staff
November 2021
The Road to Flannel: Our Newest Pajama Fabric
The Road to Flannel: Our Newest Pajama Fabric
PF:

After designing everything in a single fabric for years, what made you decide to introduce flannel? 

AV:

Flannel was a fabric that I hadn’t really considered. As a child I had flannel sheets in the winter - they were stiff and covered in pills so it wasn’t the fondest memory! However, after receiving an overwhelming amount of requests for flannel, I knew this was something we wanted to offer for our customers. We spent the last year researching and testing and have finally developed a buttery soft, lightweight flannel that’s perfect for our best selling Bagheera print.

PF:

How did you start the process of producing a new material for PF pajamas? 

AV:

My first step was to see if the mill that we work with in India had any flannels available. We found that some were too heavy and some were not soft enough - and that’s where our research began. We read countless reviews of existing flannel pajamas to figure out where issues commonly arose, and found that many flannel pajamas in the market were too scratchy, pilled after washing or created too much fuzz in the dryer. 

“We chose to use a lighter weight fabric – making it more resilient to pilling. As a result, our flannel will maintain its high quality appearance and will last multiple seasons.”
- Amy Voloshin, Founder 

The Road to Flannel: Our Newest Pajama Fabric
The Road to Flannel: Our Newest Pajama Fabric
PF:

What challenges did you face? 

AV:

Flannel is actually a process of combing and agitating the surface of cotton to comb it into a fuzz. Developing a cotton that can withstand that process and stay soft even through multiple washings was quite a challenge. The same goes for determining the weight of the fabric. We had to find a way to keep the fabric cozy while reducing the chance of pilling. Another challenge we faced involved adding our prints to the new fabric. Typically flannel is printed with very bold graphic designs that are almost cartoon-y – and that really isn’t our style! We knew we had to develop a fabric that would be delicate enough to handle our elaborate prints and the many colors we use. 

PF:

Are there any materials in the flannel that are recycled/ethically sourced?

AV:

Not for this collection, non-recycled cotton tends to last much longer as the staples (fiber length) of the cotton are longer and make for a longer lasting wear. The process of developing our flannel during the pandemic was lengthy. It’s hard to believe how long it takes to develop a core fabric for our line - one that will wash well and get better over time. When working with a new vendor, 100% organic options aren’t always initially available until you are able to put in a sizable order (and that is a true challenge for small brands looking to make organic choices!). However, we believe in continuously improving our designs and fabrics. We hope to introduce fully organic flannel by 2022.

“While I love our cotton poplin, flannel gives you a feeling of comfort and warmth because of the fuzzy handfeel. Flannel is perfect for the cold winter months and early spring.”
- Amy Voloshin, Founder 

The Road to Flannel: Our Newest Pajama Fabric
The Road to Flannel: Our Newest Pajama Fabric

Shopping the collection

We can’t wait to finally share our flannel pajamas with all of you! While we are starting the journey with our best selling bagheera print, we are hoping to offer a fuller collection of patterns and silhouettes next year! In the meantime, we hope you love how detailed the pattern came out and enjoy this new cozy fabric for the winter months. 

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PF MAG: Founder Amy Voloshin is passionate about creating a space that speaks to our brand, shares unique perspectives from sleepwear enthusiasts and finds ways to promote more thoughtful living. From teammate content to behind the scenes first looks, our blog PF Mag covers fun and not-so-simple topics on all things lifestyle - including fashion, wellness, design, travel, and home decor, as well as interviews with some of the people who inspire us most.

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