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Designing Multi-Layer Incontinence Products: A Technical Guide to Fabric Layer Combinations and Performance
Blog Summary:
Effective reusable incontinence products require strategic layering of specialized fabrics for optimal performance. Each layer serves a distinct purpose: the top layer wicks moisture away from skin, the core layer provides absorption and retention, and the barrier layer prevents leaks. Wazoodle's engineered fabrics like Zorb®, ProCool®, and ProSoft® work together as complete systems, offering solutions for various products from daily briefs to overnight protection, while maintaining sustainability through washable, eco-friendly materials.
Key Takeaways:
a. Three-Layer System is Critical – Every effective incontinence product needs a moisture-wicking top layer, absorbent core layer, and waterproof barrier layer working together.
b. Fabric Selection Impacts Performance – Different products (briefs, pads, bedding) require specific fabric combinations based on intended use, with options for light to heavy protection.
c. Sustainability Through Durability – Reusable designs using high-quality technical fabrics can withstand 300+ wash cycles, reducing waste while maintaining effectiveness.
d. Material Innovation Matters – Advanced fabrics like Zorb® can hold up to 10 times their weight in liquid, while maintaining structure and comfort through multiple uses.
When it comes to designing effective, reusable multi-layer incontinence products, success starts with what lies beneath the surface — literally. Whether you're crafting briefs, pads, inserts, or bedding protection, your fabric choices and how you layer them will determine everything from how well a product absorbs liquid to how comfortable and discreet it feels for the user. That’s because incontinence products are more than just fabric. They’re systems of performance, built with purpose. Each layer serves a distinct role — from pulling moisture away from the skin, to holding it in, to making sure it never leaks through - it’s critical to performance, durability, and comfort.
At Wazoodle, we specialize in helping manufacturers, makers, and product designers understand not just which fabrics to use, but how to combine them. Our fabric technologies like Zorb®, ProSoft®, ProCool®, and ProECO® are engineered to work together — forming complete layer systems for high-performance, reusable incontinence solutions.
This guide will walk you through the key functions of each layer — and how to select Wazoodle fabrics that work together as complete systems. You'll find use-case examples for everything from overnight briefs to booster pads, plus insights into sustainable materials and textile performance.
Whether you're creating one product or planning a production run, this guide is designed to help you build confidence through smart, fabric-first decisions.
Understanding the Function of Each Layer
At the heart of every effective incontinence product is a system — not just of fabric, but of function. When each layer plays its role in managing moisture, the result is a product that works better, feels better, and lasts longer.
Here are the three critical layers used in most multi-layer incontinence products, and what each one does.
1. Top Layer (Stay-Dry Comfort)
This is the fabric closest to the skin — and one of the most important for day-to-day comfort. Its job isn’t just to feel soft, but to keep the skin dry.
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- Function: Wicks moisture away from the skin quickly and efficiently.
- Ideal Materials: ProCool® performance fabrics — especially lightweight jerseys and interlocks with stay-dry finishes.
- Why it matters: Staying dry is essential for skin health. According to 1Concier, dry-touch fabrics help reduce skin shearing, irritation, and discomfort during prolonged wear.
2. Absorbent Core (High-Capacity Retention)
The core layer is responsible for doing the heavy lifting — absorbing and locking away moisture so it doesn’t leak or cause rewetting.
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- Function: Absorbs liquid quickly and holds it deep within the fabric structure.
- Ideal Materials: Zorb® fabrics, including First Gen and Third Gen options. These offer superior absorbency, holding up to 10 times their weight in fluid.
- Why it matters: According to the National Association for Continence (NAFC), incontinence products should absorb between 5 to 27 ounces of liquid, depending on the use case. Zorb fabrics are designed specifically for these performance demands, maintaining structure and effectiveness even after repeated use.
3. Barrier Layer (Waterproof Protection)
The outermost layer’s job is simple but critical: prevent liquid from escaping the product, while maintaining flexibility and breathability.
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- Function: Creates a reliable waterproof seal.
- Ideal Materials: ProSoft® PUL fabrics. These are engineered to be soft, flexible, and waterproof — and they retain their effectiveness through 300+ commercial wash cycles.
- Why it matters: Breathable, single-layer waterproofing helps maintain comfort without trapping excess moisture. Aeroflow Urology notes that layering multiple waterproof barriers can actually reduce performance by increasing bulk and causing condensation between layers.
By understanding the role of each layer — and choosing fabrics that are designed to excel in that role — you build a product that performs under pressure, supports skin health, and holds up over time.
Optimal Fabric Selection for Each Layer
In high-performance incontinence products, layering isn’t just about stacking materials — it’s about building a system that meets the user’s needs for comfort, absorbency, leak protection, and washability. And that starts with choosing the right fabric for each layer.
At Wazoodle, many of our core fabrics are offered in multiple performance variations — including LITE (for trim builds), Heavy Duty (for maximum capacity), Antimicrobial (for added hygiene), and Repreve® Recycled versions for eco-conscious applications. These options exist across our moisture-wicking, absorbent, and waterproof fabric lines.
Below, we’ve outlined our standard recommendations for each layer to help you build a strong foundation. But if you’re designing for specialty needs — like infection control, slim-profile garments, or sustainable product lines — these enhanced variations are also available in most product categories.
Moisture-Wicking Top Layer
Function: Pulls liquid away from the skin to keep the surface dry.
Use Case: Skin-contact layer in briefs, liners, boosters, and bedding.
✅ Recommended Fabrics:
Why These Work:
All of these fabrics offer high breathability, fast moisture transport, and a dry-touch finish. They’re also CPSIA certified — safe for prolonged skin contact and highly durable in reusable applications.
Absorbent Core Layer
Function: Rapidly absorbs liquid and retains it within the fabric.
Use Case: Core layer for pads, inserts, briefs, and mattress protectors.
✅ Recommended Fabrics:
Why These Work:
Zorb fabrics are engineered to hold up to 10 times their weight in liquid, distributing moisture throughout the core rather than allowing pooling. The 3D dimple structures increase surface area and absorption speed, while variations in fiber content offer options for organic, synthetic, or stay-dry performance.
Waterproof Barrier Layer
Function: Prevents leaks while maintaining flexibility and breathability.
Use Case: Outermost layer for incontinence briefs, pads, and bedding.
✅ Recommended Fabrics:
Why These Work:
ECO-PUL™ fabrics use solvent-free lamination and are certified food-safe, BPA-free, lead-free, and CPSIA-compliant. The 1 mil option provides flexible protection for apparel, while the 2 mil and lightweight options are great for heavier-use applications like bedding and all-day briefs.
Absorbent + Waterproof Combo Layer
Function: Combines absorbent core with integrated waterproof backing in one fabric.
Use Case: Soaker pads, single-layer liners, or compact insert builds.
✅ Recommended Fabrics:
Why These Work:
Zorb 4D Soaker fabrics feature a 3-layer engineered core (wicking face, Zorb absorbency, and ECO-PUL backing) in a single textile. This reduces sewing complexity and bulk — great for smaller applications or layered pads in high-leak areas.
🧵 Putting It Together: Layer Combinations by Product Type
Strategic Combinations by Product Type
No two incontinence products are exactly alike — and neither are the people using them. That’s why strategic fabric combinations matter. Whether you’re creating ultra-slim liners, high-capacity overnight pads, or washable bedding, the key is pairing fabrics based on user need, function, and fit.
Let’s explore a few examples based on real-world use cases.
🟩 Everyday Briefs & Underwear
These products are worn for hours at a time, often under regular clothing — so discretion and comfort matter just as much as absorbency.
Best For: Active adults, daily use, moderate protection
🟨 Overnight Pads & Diapers
Designed for heavy flow and long durations, these need maximum absorbency and durability.
Best For: Bedridden users, nighttime protection, high-capacity designs
🟦 Absorbent Inserts & Boosters
These modular components are meant to be layered inside existing products, so they focus on added capacity, without waterproofing.
Best For: Custom layering, extended wear solutions, light stress points
🟧 Bladder Control Pads & Liners
These need to be slim, fast-absorbing, and discreet. Ideal for light to moderate leaks.
Best For: Light leaks, trim designs, first-time users
🟥 Bed Pads & Bedding Protection
These need to handle heavy volume and still stay soft and stable after repeated washes.
Best For: Furniture, mattress covers, washable reusable alternatives to disposable underpads
Sustainability in Fabric Choices
Sustainability isn’t a buzzword — it’s a design choice. Every layer of a reusable incontinence product can contribute to a more sustainable textile system when the right materials are used. From how they’re made, to how long they last, to what they replace — your fabric decisions matter.
At Wazoodle, sustainability is engineered into the fabrics themselves. That includes:
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- Reusable over disposable: Every product built with our fabrics is made to be washed and reused hundreds of times — reducing landfill waste and single-use plastic pollution.
- Eco-friendly sourcing: Options like ProECO® Organic Cotton are made from certified organic fibers and processed using safer, more sustainable methods.
- Recycled content: Many of our wicking and waterproof fabrics — including select ProCool® and ProSoft® lines — are available in Repreve® Recycled versions, made from post-consumer plastic bottles.
- No harmful chemicals: All Wazoodle fabrics are free of PFAS, BPA, lead, phthalates, and heavy metals — and are CPSIA-certified for long-term skin contact and safety.
And sustainability doesn’t mean compromising on performance. Fabrics like Zorb®, for example, are engineered to replace multiple layers of conventional materials — meaning less fabric, less sewing, and a longer-lasting final product.
Whether your goal is reducing waste, lowering carbon impact, or creating safer products for end users, fabric-first thinking is a meaningful step toward more sustainable solutions.
Conclusion & Next Steps
Designing incontinence products isn’t just about function — it’s about making smart, informed choices at the fabric level. The materials you choose, and how you layer them, will shape everything from leak protection to comfort, wash durability, and sustainability.
With Wazoodle’s line of technical fabrics, you’re not just buying materials — you’re building a system. Our Zorb®, ProCool®, ProSoft®, and ProECO® brands are engineered to work together, offering complete solutions for reusable incontinence products across every user type and performance level.
Whether you’re prototyping a single product or scaling production, we’re here to support you:
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- Order swatches or sample kits to test fabrics hands-on.
- Review detailed spec sheets available on each product page.
- Reach out for custom support if you need help matching materials to your design goals.
And if you’re exploring specialized options — antimicrobial finishes, recycled inputs, or lightweight profiles — those are available too.
Start with the layer that matters most to your user, and build from there. Because a better incontinence product begins with a better fabric system.