Zorb Families Compared: Original vs 3D vs 4D vs Microfiber

The Decision You're Making

Zorb offers four distinct fabric families, each engineered for a different construction approach and use case. This guide helps you choose the right family based on how you plan to build your product—not which specific weight or thickness you need (that comes next). If you're not yet sure Zorb is the right brand for your project, start with What is Zorb? The Complete Guide to Super-Absorbent Fabrics.

The four families differ most in three areas: whether the fabric can be used as an exposed surface or must be enclosed, whether waterproof protection is built in, and what fiber types contact the skin. Once you select your family, you'll choose a weight class within that family. For weight selection guidance, see Zorb Weight Classes: LITE vs Standard vs Heavy Duty.

Understanding Your Options

Zorb Original

Zorb Original is a non-woven absorbent core designed to be hidden inside your product. It must be sandwiched between two other fabric layers before washing—exposed edges will deteriorate. This makes it the most labor-intensive option, but also the thinnest and most economical. Zorb Original does not shrink or stretch, making it dimensionally predictable for pattern cutting. Available in standard weight only.

Zorb Original Variants

Standard (W-202): Base absorbent interlining. Choose this for most hidden-core applications where antimicrobial treatment is not required—the default starting point for Zorb Original projects
Silver (W-201): Same absorbent core with Silver Plus antimicrobial treatment. Choose this when the product will be worn for extended periods between washes and odor control matters—nursing pads, incontinence inserts, or reusable menstrual products where freshness between laundering is a concern

Handling Notes for Makers

Zorb Original must be enclosed. Zorb Original is an unbonded absorbent fabric — it cannot function as a standalone layer. It must be enclosed inside a sewn product (sandwiched between other fabric layers) or quilted to a stabilizing fabric before use. Washing Zorb Original unenclosed will cause the fabric to disintegrate and may damage other items in the wash. Zorb 3D and Zorb 4D are self-contained constructions that do not require enclosure.

Zorb 3D Dimples & Diamonds

Zorb 3D is a standalone fabric family with durable knitted surfaces on both sides enclosing a Zorb 3D fiber core. Unlike Original, it does not require sandwiching—it can be used as an exposed layer or as an interlining. The three-dimensional dimple or diamond knit creates raised contact points that keep the surface drier while valleys distribute and retain liquid beneath.

Zorb 3D is available in five surface styles:

100% Organic Cotton Dimple

Standard (W-231): 550 GSM, 0.085" thickness. 100% organic cotton on both face and back throughout entire construction. Choose this when maximum natural-fiber absorption and certified organic material content are required—absorbs the most liquid per layer of any 3D style. Best for cloth diaper cores (4 layers for overnight), nursing pads, baby bibs, and any product where organic certification and highest absorption density are selling points

Stay Dry Dimple

LITE (W-228): 320 GSM, 0.050" thickness. Thinnest, fastest-drying Zorb variant. Choose this when you need hydrophobic polyester surfaces in a lightweight construction for layering—cloth diaper absorbent layers where thin profile allows multiple-layer stacking, menstrual underwear cores, or sweat management inserts
Standard (W-229): 460 GSM, 0.080" thickness. Hydrophobic polyester on both face and back. Choose this as the general-purpose Stay Dry 3D—most popular choice for menstrual products, incontinence items, and diaper inserts where dry-to-the-touch feel during extended wear is the priority
Heavy Duty (W-552): 650 GSM, 0.110" thickness. Maximum absorbency in Stay Dry surface. Choose this for overnight diapers, severe incontinence pads, or any application requiring highest capacity with hydrophobic surface that wicks moisture away from skin under compression

Bamboo Dimple

LITE (W-688): 340 GSM, 0.050" thickness. 60% bamboo viscose and 40% organic cotton. Choose this when you need the softest hand-feel in a lightweight construction—baby products, nursing pads, or layering where premium softness matters but bulk is a concern
Standard (W-234): 475 GSM, 0.075" thickness. 70% bamboo viscose and 30% organic cotton. Choose this when softness at the skin surface is the top priority—softest hand-feel in the entire Zorb lineup. Preferred by makers of premium baby products, cloth diaper inserts, reusable menstrual pads, and any direct skin-contact item where tactile comfort drives purchasing decisions
Heavy Duty (W-497): 625 GSM, 0.100" thickness. 60% bamboo viscose and 40% organic cotton. Choose this for overnight diaper cores, heavy incontinence products, or any application requiring both premium hand-feel and maximum absorption in bamboo fiber

Most Versatile Family: Zorb 3D offers the widest range of surface styles (5), fiber options (organic cotton, bamboo, polyester, blends), and weight classes (LITE through Heavy Duty). If you're unsure which Zorb family fits your project, start here—the options cover the broadest application spectrum.

Organic Cotton Dimple Blend

LITE (W-377): 300-350 GSM, 0.055" thickness. 100% organic cotton outer layers with polyester interlining. Choose this when you need organic cotton at the contact surface in a lighter-weight, more economical construction—pantyliners, light incontinence products, menstrual pads, or burp cloths where thin profile and organic surface layer are sufficient. The polyester interlining is not required for labeling disclosure
Semi-LITE (W-371): 400 GSM, 0.060" thickness. 100% organic cotton outer layers with polyester interlining. Choose this when LITE is too thin but Standard 100% Organic Cotton is more capacity than needed—provides balanced organic surface construction for moderate-absorbency applications

Diamond

Standard (W-516): 500 GSM, 0.080" thickness. Tri-blend construction with one side of 70% bamboo viscose, 30% organic cotton, and the other side of wicking polyester. Choose this when you need a balance of absorption capacity and faster dry-back time—the polyester content accelerates drying compared to all-natural styles while maintaining natural fiber absorption. The diamond texture creates compression-resistant structure that maintains absorption pathways under pressure. Best for products requiring quick turnaround between uses: hair towels, burp cloths, or menstrual pads where faster drying matters alongside absorption performance

Available across multiple weight classes (LITE, Semi-LITE, Standard, Heavy Duty) depending on surface style. To compare weight classes, see Zorb Weight Classes: LITE vs Standard vs Heavy Duty.

Zorb 4D

Zorb 4D is an all-in-one laminate combining a Zorb 3D absorbent core with an embedded polyurethane waterproof film and backing fabric—delivering absorption and leak protection in a single layer. This eliminates the need to source and sew a separate waterproof fabric. All seams must be waterproof-sealed or fully enclosed—needle holes in unsealed seams compromise the barrier.

Absorption Trade-Off: The integrated lamination in Zorb 4D reduces absorption capacity compared to using Zorb 3D + ProSoft PUL as separate layers. You're trading maximum capacity for construction simplicity. If absorption density is your top priority, see Zorb 4D vs Zorb 3D + ProSoft PUL: All-in-One vs Multi-Layer Systems.

Zorb 4D is available in two surface styles—Stay Dry and Organic Cotton—each offered in V1 and V2 versions with meaningfully different constructions, not just minor revisions. Choosing the right version requires understanding what each backing and film thickness delivers.

Zorb 4D Stay Dry Dimple CORE PUL

V1 Stay Dry (W-526): ProCool Performance Interlock backing, 450–500 GSM, 0.070" thickness. Choose this as the general-purpose Stay Dry 4D—slightly heavier construction provides a more substantial hand-feel suited for training pants, pet pads, changing pads, and mattress protectors where the thicker profile is not a limitation
V2 Stay Dry (W-647): Thinner and lighter profile at 425–475 GSM and 0.060" thickness. Choose this when a slimmer, more discreet construction matters—customer-verified for menstrual pads and period underwear where the thinner profile integrates better into garment-style products. Frays at cut edges and requires serging or binding
Stay Dry Heavy Duty (W-372): Heaviest Stay Dry 4D option for maximum absorption capacity in all-in-one construction—overnight diapers, heavy incontinence, and high-volume pet training pads

Critical Layering Requirement for Zorb 4D: When using Zorb 4D in multi-layer constructions, you MUST add a stay-dry wicking layer between the Zorb 4D and skin contact. The integrated lamination in Zorb 4D places the waterproof barrier immediately behind the absorbent core, eliminating the natural wicking pathway that exists in modular systems. Without a dedicated wicking top layer (ProCool or other stay-dry fabric), liquid sits at the surface instead of distributing through the absorbent core. This applies to ALL Zorb 4D products regardless of surface style.

Zorb 4D Organic Cotton Dimple CORE PUL

V1 Organic Cotton (W-492): Organic cotton dimple face with ProCool Performance Interlock backing, 1-mil PU film, 650–700 GSM, 0.140" thickness. Choose this when you want organic cotton at the skin-contact surface but need a lighter backing layer. The ProCool polyester backing means this version is not 100% organic cotton throughout
V2 Organic Cotton (W-626): 100% organic cotton throughout all textile layers including organic cotton jersey backing, 2-mil PU film (thicker waterproof barrier), 675–725 GSM, 0.150" thickness. Choose this when full organic certification throughout every layer is required; best suited only for flat protective pad applications such as changing pads, crib protectors, incontinence underpads, and pet training pads

Zorb Microfiber

Zorb Microfiber is a 100% polyester family with single-sided constructions optimized for cleaning, toweling, and high-capacity absorption. Zorb Microfiber absorbs up to 8 times its weight in under 2 seconds—lower capacity-to-weight than 3D and 4D, but with dirt-trapping and surface-cleaning characteristics that natural-fiber Zorb families do not provide. Available in Standard, Heavy Duty, and Ultra Heavy Duty weights.

Zorb Microfiber Loop Terry

Standard (W-439): 200 GSM, 0.490" thickness. Soft absorbent loops on one side, smooth flat back. Choose this for medium-weight applications where cushioned texture and moisture interaction matter—unpaper towels, cleaning cloths, athletic sweatbands, or cloth diaper cores where the thinner profile allows for multi-layer stacking
Heavy Duty (W-350): 515 GSM, 0.066" thickness. Single-sided loop terry with increased absorption capacity. Choose this when you need higher liquid volume management in a single layer—cloth diaper inserts for heavy wetters, menstrual pad cores, pet training pads, or reusable household textiles requiring fast capture without multiple layers
Ultra Heavy Duty (W-387): 680 GSM, 0.086" thickness. Maximum absorption capacity in loop terry construction. Choose this for industrial-strength applications requiring the highest liquid management in a single pass—heavy-duty mop pads, bath towels where rapid absorption is critical, or severe incontinence products where maximum capacity with surface dryness is non-negotiable

Zorb Microfiber Fleece

Heavy Duty (W-424): 480 GSM, 0.065" thickness. Brushed pile on one side, smooth flat back. Choose this when trapping particulates alongside liquid matters—the pile surface captures fine debris that loop construction passes through. Best for dusting cloths, polishing applications, industrial wipe-down tasks, or mop pads where dirt capture is as important as liquid absorption

Different Application Domain: Zorb Microfiber is the only Zorb family engineered for cleaning and surface work rather than body-contact products. The 100% polyester construction and loop/fleece surfaces trap dirt and debris that natural-fiber Zorb families don't capture. Choose this for unpaper towels, mop pads, and cleaning cloths—not for diapers or menstrual products.

Head-to-Head Comparison

Criteria	Original	3D	4D	Microfiber
Absorption Speed	Under 2 seconds	Under 2 seconds	Under 2 seconds	Under 2 seconds
Capacity (by weight)	Up to 10x	Up to 10x	Up to 8x	Up to 8x
Standalone Use	No — must be sandwiched	Yes	Yes	Yes
Waterproof Built In	No	No	Yes	No
Skin-Contact Surfaces	None — hidden layer	4 surface styles	2 surface styles	2 constructions
Fiber Options	Cellulosic/synthetic blend	Organic cotton, bamboo, polyester, tri-blend	Organic cotton, polyester	100% polyester
Construction Complexity	Requires enclosing layers	Ready to use or interline	Ready to use, but seams must be sealed	Ready to use
Weight Classes Available	Standard only	LITE through Heavy Duty	Varies by style	Standard through Ultra Heavy Duty
Cost Tier	Lowest	Mid-range	Highest	Mid-range

All Zorb families share under-2-second absorption speed, Ready-AbZORB pre-activation (no pre-washing required), CPSIA certification, Forever Chemicals-Free verification, and Made in USA manufacturing. The families differ in construction approach, surface fiber options, and whether waterproofing is integrated.

Capacity Note: Zorb Original and 3D achieve up to 10x weight capacity. Zorb 4D achieves up to 8x — the integrated lamination that adds waterproof protection reduces absorption capacity compared to standalone 3D. Zorb Microfiber achieves up to 8x with superior dirt-trapping capability that other families do not provide. Choose between families based on construction approach and application needs, not capacity numbers alone.

Which Family Is Right for Your Project?

Start with Your Construction Approach

Your priority is lowest material cost and you're comfortable enclosing the absorbent layer between two other fabrics → Zorb Original. This is the right choice when absorption is a hidden function inside a product you're building from multiple fabric layers. Original gives you full control over both the skin-contact and backing fabrics while keeping the absorbent core thin and economical.

You want a standalone absorbent fabric that can be used as an exposed surface or as an interlining without enclosure → Zorb 3D. This is the broadest family with the most surface styles, fiber options, and weight classes—covering everything from lightweight panty liners to heavyweight overnight inserts.

You need absorption and waterproof protection in a single fabric to reduce construction steps and component sourcing → Zorb 4D. This is the right choice when simplifying your product build matters and you want one fabric doing two jobs. All seams require waterproof sealing, and the integrated lamination reduces absorption capacity versus separate layers. For details on this trade-off, see Zorb 4D vs Zorb 3D + ProSoft PUL: All-in-One vs Multi-Layer Systems.

Your product involves cleaning, scrubbing, or toweling where trapping particulates matters alongside liquid absorption → Zorb Microfiber. This is the only Zorb family engineered for surface cleaning—the loop or fleece construction captures dirt and debris that natural-fiber Zorb fabrics pass through.

Then Narrow Your Surface Style

Once you've chosen Zorb 3D or 4D, the surface style determines what fiber contacts the skin and how the surface manages moisture:

Skin sensitivity or organic certification required → Organic Cotton Dimple. Both 3D and 4D versions feature 100% organic cotton face fabric, making this the right choice for certified organic product lines, baby products where natural fiber content is a selling point, or any application where chemical-free skin contact is the primary concern. Organic Cotton also delivers the highest per-layer absorption of any 3D style.

Dry-to-the-touch feel is the priority → Stay Dry Dimple. The hydrophobic polyester face wicks liquid through to the absorbent core rather than saturating at the surface. This is the most popular choice for menstrual products, incontinence items, and any application where the user needs to feel dry between changes. Available in both 3D and 4D versions with the widest range of weight classes.

Maximum softness at skin contact → Bamboo Dimple (3D only). The 70% bamboo viscose surface is the softest in the entire Zorb lineup—preferred by makers of premium baby products, nursing pads, and skin-contact items where hand-feel drives purchasing decisions. Not available in 4D.

Balanced absorption and drying speed → Diamond (3D only). The tri-blend construction absorbs well and dries faster than all-natural styles due to polyester content. A good choice when you want natural fiber absorption without the longer drying times of 100% cotton or bamboo. Not available in 4D.

Cleaning and toweling applications → Loop Terry for maximum liquid pickup with soft surface texture, or Fleece for brushed pile that traps particulates. Both are 100% polyester with single-sided construction.

Not sure which style? Order swatches before committing to yardage. Surface feel, thickness, and drape vary significantly between styles, and hands-on testing with your specific product pattern will confirm the right choice faster than any comparison chart.