When it comes to buying board shorts, the fabric makes all the difference. Whether you're surfing, swimming, or just hanging at the beach, the material of your board shorts determines everything — comfort, drying speed, flexibility, and durability.
In this guide, we compare the most popular board shorts fabrics, breaking down their pros and cons to help you make the best choice.
Polyester (Recycled & Virgin)
Polyester is the most commonly used fabric in board shorts today — and for good reason.
Pros:
- Quick-drying: Doesn’t hold water like cotton.
- Highly durable: Resistant to UV rays, salt, and chlorine.
- Colorfast: Retains dye extremely well.
- Affordable: A great price-to-performance ratio.
- Eco-friendly options: Recycled polyester (rPET) is widely available.
Cons:
- Less breathable than natural fibers.
- May retain odor without antimicrobial treatments.
Industry Insight:
In 2024, more than 70% of performance board shorts use polyester blends, especially with 4-way stretch. Big brands like Hurley and Volcom rely on polyester for its reliability and versatility.
Nylon (Polyamide)
Nylon offers a smooth, lightweight feel and is a favorite for certain beach styles.
Pros:
- Silky soft and lightweight.
- Strong tensile strength — resists tearing.
- Comfortable against the skin.
Cons:
- Weaker UV and chlorine resistance than polyester.
- Holds water longer, making it slower to dry.
- Fades faster under sun exposure.
Industry Insight:
Nylon was popular in the 80s and 90s. Today, it’s mostly used in retro or fashion-oriented designs, not performance surf wear.
Spandex/Elastane Blends (4-Way Stretch)
These blends combine polyester or nylon with spandex (aka elastane) for maximum mobility.
Pros:
- Excellent stretch: Perfect for surfing and sports.
- Comfortable fit that moves with your body.
Cons:
- More delicate: Can wear out faster under heat or chlorine.
- Shorter lifespan unless high-quality fibers are used.
Industry Insight:
A common blend is 90% polyester + 10% spandex. Look for premium elastane brands like LYCRA® for better durability and recovery.
Cotton and Cotton Blends
Cotton isn’t ideal for active water use — but it still has its place in beach fashion.
Pros:
- Soft, breathable, and natural.
- Great for casual beachwear.
Cons:
- Absorbs water, making it heavy and slow to dry.
- Shrinks easily and wears out faster under harsh conditions.
Industry Insight:
Cotton-polyester blends (e.g., 60/40) are often used for hybrid shorts meant for walking the boardwalk rather than hitting the waves.
Microfiber (Brushed Polyester/Nylon)
Microfiber is essentially a soft, brushed version of polyester or nylon.
Pros:
- Extremely soft with a “peach skin” feel.
- Dries quickly and is comfortable to wear.
- Budget-friendly.
Cons:
- Low elasticity unless blended with spandex.
- Less performance-focused — better for lounging than surfing.
Industry Insight:
Microfiber dominates the affordable swimwear market. It's widely used in mass retail lines like Target or Walmart.
Bonus: High-Performance Technical Blends
Top brands now use engineered fabric weaves like:
- Ripstop stretch
- Dobby 4-way stretch
- Hydrophobic-coated polyester
These fabrics are designed for maximum performance, including features like:
- Ultra-fast drying
- Chafe-resistance
- Compression support
Fabric Comparison Table
| Fabric Type | Stretch | Dry Time | Durability | Comfort | Best Use Case |
|---|---|---|---|---|---|
| Polyester | ❍❍ | ★★★★☆ | ★★★★☆ | ★★★☆☆ | All-purpose surfing |
| Nylon | ❍❍ | ★★★☆☆ | ★★★☆☆ | ★★★★☆ | Retro/fashion styles |
| Poly-Spandex Blend | ★★★★☆ | ★★★★☆ | ★★★☆☆ | ★★★★★ | Surfing & water sports |
| Cotton | ☆☆☆☆☆ | ☆☆☆☆☆ | ★★☆☆☆ | ★★★★★ | Casual beach lounging |
| Microfiber | ❍ | ★★★☆☆ | ★★★☆☆ | ★★★★☆ | Budget-friendly swimwear |
Final Expert Advice
- For surfers: Go with a 4-way stretch polyester-spandex blend. It offers flexibility, quick-drying properties, and is built for movement.
- For casual wearers: Choose cotton blends or microfiber for comfort and softness.
- For sustainability: Opt for recycled polyester (rPET) — just as durable and better for the planet.
Expert Takeaway
After 15 years in the board shorts industry, I can say this:
The future is stretchy, sustainable, and surf-ready. Today’s best board shorts aren’t just quick-drying — they move with your body, hold up under sun and salt, and are made from eco-responsible materials. Choosing the right fabric is step one in finding a pair of board shorts you'll wear for years.
Need help choosing the right fabric for your custom board shorts line? Get in touch — we help brands source, develop, and manufacture premium board shorts at scale.
