Neurophysiological, Sensory, and Environmental Implications of Nylon vs. Polyester in Conscious Design

Abstract This paper examines nylon (polyamide) and polyester (PET)—the two most widely used synthetic fibers in modern apparel—through an integrated framework combining material science, environmental assessment, and wearer-centered neurophysiological and sensory comfort. While both fibers originate from petrochemical feedstocks, their molecular architectures, manufacturing pathways, and interactions with the human body differ substantially. Drawing on life-cycle assessments (LCAs), textile chemistry, regulatory literature, and over a decade of professional design observation, this study argues that regenerated nylon systems—particularly nylon 6 and nylon 6,6—offer superior alignment with both human sensory–neurophysiological comfort and circular material economies when compared to conventional polyester. Nylon’s amide-based molecular structure enables moderate moisture regain, improved electrostatic charge dissipation, and greater thermophysiological stability at the skin–textile interface. Polyester’s ester-based structure, by contrast, exhibits low hygroscopicity, higher static accumulation, and greater reliance on heavy-metal catalysts and energy-intensive dyeing processes. Beyond environmental metrics, this paper introduces neurophysiological comfort as an operationalized concept defined by the convergence of bioelectrical comfort and thermophysiological stability as perceived and integrated by the wearer’s nervous system. By integrating embodied design insight with measurable physical phenomena, the analysis reframes textile sustainability as both a scientific and sensory design question. The findings suggest that regenerated nylon systems provide a materially, physiologically, and strategically robust pathway for brands seeking long-term value, authentic differentiation, and closed-loop circularity.