You've done your research, read the labels, and finally found that perfect natural fiber activewear brand.

But then you flip the care label and see it: 10% elastane. Your heart sinks.

Is 100% plastic-free activewear possible?

In this guide, we'll cover:

• Why elastane is still used in some high-performance activewear (even natural ones)
• What makes conventional stretch fibers a problem for skin and the planet
• Whether safer, more sustainable alternatives exist (hint: they do!)
• How Tripulse is tackling the plastic-free activewear dilemma
• Simple ways you can find clean, stylish and durable activewear for a better way to move and live

Key Takeaways

• 100% plastic-free activewear isn't always possible yet. Stretch is essential in some pieces like leggings and sports bras.
• Conventional elastane is made with harsh chemicals, isn't biodegradable, and sheds microplastics.
• Safer stretch alternatives exist, like ROICA™ V550 and EF, both certified non-toxic and lower impact.
• The healthiest choice? Activewear made from 100% certified natural performance fabrics (like TENCEL™ Lyocell), or mostly natural fibers paired with skin-safe stretch like ROICA™.

How to Spot Skin-Safe Activewear: Powerful Tips

Step 1: Look for Skin-Safe Certifications

These show that the materials have been tested for harmful substances. And not just in the main fabric, but stretch fibers too!

Trusted third-party certifications to look for include:

• OEKO-TEX® Standard 100: Ensures every component is tested for harmful substances.
• Cradle to Cradle: Assesses material health, circularity, and environmental impact.
• Bluesign®: Focuses on safe, cleaner textile production.
• REACH compliant: Ensures compliance with EU chemical safety standards.
• Global Organic Textile Standard (GOTS): Covers organic fibers and strict environmental and social criteria.

Step 2: Do Your Research

A trustworthy brand will be transparent about every fiber used, including elastane.

• Avoid vague marketing terms like "eco-friendly stretch" or "sustainable performance" without proof.
• Look for details on where each material comes from, how it's made, and what it's treated with.
• The best brands explain why they use what they use, so you can understand the balance between performance, comfort, and sustainability.

Step 3: Choose Activewear With a High Certified Natural Fiber Content

For healthier movement, your activewear should be made mostly from clean, certified natural fibers.

But keep in mind:

• Not all natural fibers are created in the same way. Conventional fabrics like cotton and rayon can still have high environmental impacts and be treated with harsh chemicals.
• Some natural fibers don't perform well during intense movement. Cotton, for example, traps heat, moisture, and odors when you sweat.

Pro tip: Choose natural fibers that are certified skin-safe and designed to naturally perform.

We've found TENCEL™ Lyocell to be one of the highest-performing materials for activewear. It's breathable, luxuriously soft, and produced in a closed-loop, low-impact system that meets strict health and sustainability standards.

What Is Elastane?

Elastane is a synthetic fiber best known for its incredible stretch and ability to snap back to shape. It can expand up to five times its length and still snap back into shape.

This is why it's used in activewear to create flexible, body-hugging fits.

Even though elastane usually makes up only a small part of a garment, it has a big impact on movement, support, and comfort.

You may also know it as spandex (the generic name) or Lycra® (the branded version by DuPont).

What is Elastane Made From and How is it Made?

Elastane is made from polyurethane - a soft, elastic type of plastic derived from petroleum-based chemicals.

It was first developed in the 1950s by DuPont as a more durable, stretchy alternative to rubber.

Today, nearly all (95%) of elastane is produced using a method called dry spinning. This is a highly industrial process that transforms liquid plastic into stretchy fibers.

Here's a simplified look at how elastane is made:

• It starts with synthetic substances like diisocyanates and macroglycols.
• These are combined to create a stretchy liquid known as a prepolymer.
• The prepolymer is reacted with other chemicals, called chain extenders, which form polyurethane.
• Polyurethane is then dissolved in a powerful solvent and spun into fibers using the dry spinning method.
• Those fibers are then solidified, stretched, and finished to be used in fabric blends.

Is Elastane Toxic?

Elastane gives clothes that feel-good stretch, but the way it's made is oftentimes far from clean.

It's produced and treated with a cocktail of chemicals - some of which are known to be toxic.

Elastane is ranked Class E (least sustainable) by the Made-By Environmental Benchmark for Fibers. This rating is based on human toxicity risks as well as ecological impact.

Common Chemicals Used to Make Elastane

Chemical	Purpose	Key Concerns
Isocyanates	Core polyurethane ingredient; gives elastane its stretchiness	Potential carcinogen; skin & respiratory irritant
DMF & DMAC	Solvents in dry spinning	Toxic; EU-restricted; linked to allergies & liver damage
Urethane	Polyurethane building block	Suspected carcinogen (NIH)
Bisphenols (BPA, BPS)	Improves stretch/flexibility	High levels found in spandex blends; linked to hormone disruption, fertility & metabolic issues
UV stabilizers	Sun/UV protection for fibers	EU flags certain types as persistent, bioaccumulative, toxic

Can Our Bodies Absorb Chemicals From Elastane Clothing?

Your skin acts as a protective barrier to the outside world. However, it's not completely impenetrable.

Research shows that chemical residues can linger in clothing after production - and some may transfer to your skin.

One way this happens is through microplastic shedding.

Elastane, like all plastic-based fabrics, sheds tiny fibers during wear, washing, and disposal. These microplastics can act like "Trojan horses," carrying harmful textile chemicals deeper into the body.

Studies suggest that microplastics (and the chemicals attached to them) can:

• Enter the skin through sweat glands, hair follicles, or cuts
• Become more bioavailable when the skin is warm or sweaty (e.g. during exercise)
• Accumulate in the body over time - they've already been found in the lungs, placenta, and the brain

Dr. Julian Koschmieder, OEKO-TEX® Product Manager, explains:

"Especially those people who do sports for health reasons should not only think about the activity itself [...] They can be absorbed primarily through the skin, but also by inhalation in case of toxic chemicals that evaporate or through oral absorption."

Learn more: How to Avoid Microplastics in Clothing: A Step-by-Step Guide

Can Elastane Cause Skin Irritation?

For sensitive skin, elastane can be a problem.

The issue isn't usually the fiber itself but the chemicals used to make it.

Residues can remain in the fabric and trigger reactions from mild itching and redness to swelling and blistering.

Flare-ups are more common with tight-fitting pieces like leggings, sports bras, or waistbands that sit close to the skin.

Some studies also suggest elastane chemicals may disrupt the skin's microbiome. For example, isocyanates can reduce healthy skin bacteria and increase harmful strains like Staphylococcus aureus.

Patch-test studies have also found that polyurethane-based products can trigger allergic contact dermatitis, even at low levels.

Pro tip: If you have an elastane allergy, look for activewear made with skin-safe, non-toxic elastane alternatives like ROICA™ V550 or EF. More on this later!

Do All Activewear Types Need Elastane?

Not all activewear needs synthetic stretch.

Some pieces perform beautifully without it. Others need elastane to provide support and movement.

Items that work 100% plastic-free:

• Loose-fit workout tops
• Flowy yoga shirts
• Relaxed training tees
• Workout accessories

Items that need some stretch for function:

• Compression leggings
• Supportive sports bras
• Fitted running or gym shorts
• Body-hugging base layers

Natural Fibers Go a Long Way (But Not All the Way!)

Plant-based fibers already deliver a lot when it comes to performance.

Take TENCEL™ Lyocell - our signature activewear fabric. It's breathable, soft on the skin, and naturally resists moisture and odors. Best of all, it does all this without synthetics or toxic finishes.

Plus, we use smart knitting techniques to build in as much natural stretch as possible.

But here's the truth: for performance-heavy pieces, natural stretch still has limits. Plastic-free stretch isn't fully there yet but skin-safe, certified alternatives to conventional elastane do exist.

We'll dive into those next.

Meet ROICA™ V550 and ROICA™ EF: A Safer, Smarter Stretch

ROICA™ is a next-generation stretch fiber made by Japanese innovators Asahi Kasei.

It's still synthetic but unlike conventional elastane, it's designed with both health and sustainability in mind. From how it's made to how it behaves on your skin (and in nature), every step of its lifecycle is considered.

That's why for our skin-tight activewear, we use ROICA™ V550 and ROICA™ EF - two certified alternatives to elastane. Both deliver the stretch you need, while being kinder to your skin and gentler on the planet.

What is ROICA™ V550?

ROICA™ V550 is a breakthrough biodegradable stretch yarn. In the right industrial composting conditions, it decomposes into CO2 and water leaving no toxic residues behind.

It's not home-compostable yet, but it's a big step forward from conventional elastane which never fully breaks down.

ROICA™ V550 is also certified by leading third-party standards:

• OEKO-TEX® Standard 100 Class I - one of the world's trusted textile safety certifications. Class I is the strictest level, meaning fabrics that meet this standard are safe even for babies' skin.
• Cradle to Cradle (Material Health Gold) - every ingredient is assessed and considered safe for human and environmental health. Free from carcinogens, hormone disruptors, and other substances of concern.

What is ROICA™ EF?

ROICA™ EF is made with 58% recycled content. This is a big step forward, especially since regular elastane is 100% reliant on virgin plastics.

It also uses less energy, cutting greenhouse gas emissions by around 30% during production.

Like V550, EF is certified by trusted third parties, including:

• OEKO-TEX® Standard 100 Class I
• Recycled Claim Standard (RCS) - verifies the recycled materials used.

Regular Elastane vs ROICA™: Performance, Health and Nature

Regular Elastane vs ROICA™: Performance and Skin Health

Regular Elastane

• Durable and stretchy
• Often made with toxic chemicals like carcinogens and hormone disruptors
• Not always certified, so chemical safety isn't guaranteed
• Poor breathability and residual toxic chemicals can irritate skin - especially during movement and sweat
• Sheds microplastics that can carry toxins into the body

ROICA™V550 and EF

• Delivers the same strong, flexible stretch as regular elastane
• Certified non-toxic by trusted third-party certifications
• Designed to be itch-free and safe for even the most sensitive skin

Regular Elastane vs ROICA™: Environmental Impact

Regular Elastane

• Energy-intensive, fossil fuel dependent, and uses toxic chemicals
• Hard to recycle - even small amounts can block recycling systems
• Most stretchy clothes end up in landfill or incineration
• Doesn't biodegrade - sheds microplastics every time it's worn, washed, or thrown away
• Just 2% elastane in a cotton blend can cause significant microfiber shedding in laundry
• Polyurethane fibers are considered some of the most persistent and toxic forms of microplastics

ROICA™ V550 and EF

• Both V550 and EF are low-impact and built for circularity
• EF uses 58% recycled content, reducing dependence on virgin resources
• V550 is designed to break down in nature. In ISO14855-1 testing, V550 showed around 50% biodegradation in 24 months - regular elastane showed none.
• Supply chain built to reduce environmental harm at every stage:
  • 60% emissions reduction target by 2030
  • 99.6% waste diversion across operations (2023)
  • Energy-efficient equipment and renewable energy certificates
  • Water reuse and strict chemical controls
  • Active biodiversity and conservation programs

Real-World Results: What Our Community Says About Safer Stretch

We recently surveyed 50 Tripulse customers (June 2025) to understand how our TENCEL™ Lyocell and ROICA™ activewear performs compared to synthetic and other natural activewear brands.

And the results speak volumes!

Tripulse’s Plastic-Free Activewear Journey: A Q&A with Founder Franziska Mesche

Q: Why does Tripulse use synthetic stretch at all? Isn't plastic-free activewear the goal?

A: "For certain pieces - like leggings and sports bras - that need to sit skin-tight and support movement, extra stretch is essential.

We've come a long way with material innovations and special knitting techniques that make TENCEL™ Lyocell (our signature fabric) naturally more stretchy. But to ensure high performance and maximum comfort, we need to add some additional stretch.

All too often, frustrated women approach me and share their discouraging experience of wearing nearly 100% cotton leggings. After just a few wears, they lose shape, tear easily, and become unwearable.

For plastic-free activewear to truly work and be loved by users, performance needs to be there."

Q: What made you want to challenge the way activewear is typically made?

A: "It was my mission from day one to create high-performing activewear free from harmful plastics and toxins.

When I started Tripulse, I was told repeatedly, 'What you're trying to create is impossible. You have to use polyester or synthetics to achieve performance. Natural materials just won't cut it.'

That's the story I kept hearing. And while I value the experience of those in the industry, I'm proud that I didn't follow their advice.

Real change means doing things differently. So I kept looking for a fabric that could meet all my standards."

Q: What was the process of finding the right fabric like?

A: "After a lot of trial and error, I finally found the right material.

Our signature fabric is a unique composition of the certified wood-based fiber TENCEL™ Lyocell. It's 100% plastic and toxin-free and has amazing performance features. TENCEL™ is naturally breathable, odor-resistant and doesn't cause any skin irritations.

That said, finding a natural fabric that performs well isn't easy. This is especially true when it comes to details like trims, threads, and the stretch needed for skin-tight pieces.

While we've managed to make all our trims - embroidery, care labels, and prints - plastic-free, replacing conventional elastane has been the toughest challenge."

Q: Why did you choose ROICA™ for your stretch fiber?

A: "We didn't settle for conventional elastane. We turned every stone to find the 'second best option'. While what we've gone for isn't 100% natural, it's already so much better in terms of health and environmental aspects while still being high-performing.

For instance, we use ROICA™V550 in all of our Original leggings and shorts.

Q: How close is Tripulse to being 100% plastic-free?

A: "We're getting closer every day. Right now, around 95% of our activewear is made from 100% plastic-free, wood-based TENCEL™ Lyocell. The remaining 5% includes more health- and eco-conscious versions of elastane.

Our philosophy is to work at the intersection of non-toxic natural fabrics, high performance, and true sustainability."

More Helpful FAQs

Is Elastane a Healthy Fabric?

Most conventional elastane isn't considered a "healthy fabric". This is because it's often processed with harsh chemicals and not certified for skin safety.

For peace of mind, look for clothing made with certified non-toxic and low impact versions like ROICA™ V550 or EF.

Is Elastane Plastic?

Yes - elastane is a fully synthetic fiber. It's made from a type of petroleum-based plastic called polyurethane.

The production process involves a complex mix of solvents and chemical treatments to create elastane's ultra-stretchy fibers.

Is Elastane the Same as Spandex and Lycra?

Yes - elastane, spandex and lycra are the same fiber. Spandex is simply the generic name used mainly in the U.S.

Lycra is a branded version of elastane developed by DuPont.

Does Natural Activewear Contain Elastane?

Sometimes natural activewear contains elastane when stretch and support are essential.

You'll often find small amounts of elastane in natural fiber leggings, sports bras, or fitted shorts. This is to help them move with your body and hold their shape.

But not every piece needs it. For example, our workout tops are made from 100% TENCEL™ Lyocell, using a special knit that allows for natural stretch.

Pro tip: When elastane is needed, choose safer options. We use ROICA™V550 and EF - a certified, low-impact stretch that's kinder to your skin and the planet.

Is Elastane Breathable?

Elastane isn't a breathable fabric. It's hydrophobic, which means it repels moisture instead of wicking it away. Sweat then stays on the skin, leading to that sticky, smelly feeling during and after workouts.

Synthetic blends with elastane, such as polyester or nylon, tend to be even less breathable. One study found that they trap far more heat and odors compared to natural fibers.

For more breathable performance, choose natural fibers like TENCEL™ Lyocell, paired with a smart, non-toxic stretch fiber like ROICA™ V550.

Does Elastane Shed Microplastics?

Elastane is a synthetic fiber. This means it sheds microplastics during washing, wear and when thrown away.

Polyurethane-based microplastics, like those from elastane, may be among the most persistent and harmful.

Does Elastane Contain PFAS?

Elastane itself isn't made from PFAS, but it's often treated with them - especially in activewear blends.

PFAS, also known as "forever chemicals," are added to sporty attire to boost moisture control and stain resistance.

Tests have found PFAS to be lurking in the threads of major activewear brands - including Lululemon.

According to one recent study, PFAS can readily absorb through human skin from clothing fabric.

Learn more: How to Avoid PFAS in Clothing: Practical Tips

Is Elastane an Endocrine Disruptor?

Elastane polymers aren't considered endocrine disruptors. That said, the concern lies in the additional chemicals used to make, dye, print, and finish garments mixed with elastane.

For example, studies have detected residues of phthalates, benzothiazole, and BPA in conventional elastane-blend clothing. All three are linked to hormone disruption.

To reduce your risk, choose skin-safe pieces certified by OEKO-TEX® STANDARD 100. This ensures every thread is tested for harmful substances.

Is Elastane Carcinogenic?

Elastane is made from polyurethane which is considered carcinogenic due to some of the chemicals it's processed with.

For example, urethane used to make polyurethane is considered "reasonably anticipated to be a human carcinogen" by the National Institutes of Health.

Conclusion and Next Steps

Plastic-free isn't possible for all high-performing activewear just yet. But that doesn't mean we have to settle for toxic materials that harm our health and the planet.

Your Next Steps

1. Check your current activewear labels (knowledge is power)
2. Prioritize replacing items worn closest to skin
3. Ask your favorite brands about their elastane sources
4. Share this guide with your workout community

Remember: The goal isn't perfection, it's progress. Choose the safest options available today while supporting brands working toward tomorrow's solutions.

For more, visit:

• How Skin-Friendly Activewear Can Change Your Workout for the Better
• Your Ultimate Guide to Toxins in Clothing for a Healthier You
• How to Avoid Microplastics in Clothing: A Step-by-Step Guide
• How to Avoid PFAS in Clothing: Practical Tips
• What is TENCEL™ Lyocell? Everything You Need to Know

About the Author

This article is written in collaboration with Christie Johnson (B.A. Hons, PGCert), a health and sustainability writer with over five years of experience in the conscious fashion space. She explores how the clothes we wear affect our skin, well-being, and the planet - translating complex ideas into clear, empowering insights. With a strong foundation in clean materials and non-toxic living, Christie's work is grounded in integrity, curiosity, and a deep care for people and the world we share.