Zorb 4D vs Zorb 3D + ProSoft PUL: All-in-One vs Multi-Layer Systems

The Decision You're Making

If your product needs both absorption and waterproof protection—cloth diapers, menstrual pads, incontinence products, pet training pads, mattress protectors—you face a fundamental construction choice: use a single fabric that does both, or build separate layers that each do one job. This isn't a question of which Zorb family to choose (that's covered in Zorb Families Compared) or which weight class you need (see Zorb Weight Classes: LITE vs Standard vs Heavy Duty). This is about how you want to architect your product.

The two approaches are Zorb 4D (integrated all-in-one laminate) and Zorb 3D paired with ProSoft® PUL (modular multi-layer system). Both deliver absorption with leak protection. They differ in construction complexity, absorption efficiency, customization flexibility, and long-term economics.

Understanding Your Options

Zorb 4D embeds a polyurethane waterproof film between the Zorb 3D absorbent core and a backing fabric, creating a single fabric that absorbs liquid and prevents leaks.

Key Advantages

Cut one piece of fabric instead of layering separate absorbent and waterproof components
Faster construction—fewer pieces to cut, fewer seams to sew
Thinner overall profile than equivalent multi-layer assemblies (no air gap between layers)
Quieter operation—SilentFlex ECO-Thermal bonding eliminates plastic crinkle sound

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.

Critical Trade-Offs

Absorption capacity of up to 8× weight versus Zorb 3D's up to 10× — the lamination process that adds waterproof protection constrains the 3D fiber structure that enables rapid liquid distribution
All seams must be waterproof-sealed; unsealed needle holes compromise the embedded barrier and cause leaking. This adds a construction step not present in modular systems
Fixed layer configuration; cannot customize or replace individual components
For many applications (menstrual pads, daytime cloth diapers, light to moderate incontinence), the reduced capacity is still more than adequate
For heavy-duty overnight use or high-volume containment, the capacity loss may matter

Available in Stay Dry and Organic Cotton surface styles across V1 and V2 configurations. For detailed within-4D comparisons, see Zorb Families Compared.

Zorb 3D + ProSoft PUL: The Modular Approach

The modular approach uses Zorb 3D as the absorbent layer and ProSoft® PUL (polyurethane laminate) as a separate waterproof barrier. You sew them together during construction, but each layer operates independently.

Key Advantages

Full absorption capacity from the Zorb 3D layer — up to 10× weight versus 4D's up to 8×
Swap individual layers without replacing the entire product—extend product life and create replacement parts revenue stream
Complete flexibility to customize the layer stack for your specific application
Choose exactly which weight of Zorb 3D, which type of ProSoft PUL, and whether to add additional layers like wicking top sheet or comfort backing
Standard sewing techniques—no waterproof seam sealing required

Trade-Offs

Requires sourcing and cutting two separate fabrics
More seams to plan and sew—longer construction time
More material handling during production
Slightly thicker total profile—separate layers plus seam allowances create air gap
Sound characteristics depend on which ProSoft PUL variant you select. If you're using ProSoft® PUL then it's Silent; but other PUL can make sounds

This approach works best when absorption performance, customization flexibility, or component replacement capability outweigh the additional construction complexity.

For an introduction to ProSoft PUL waterproof fabrics, see the ProSoft Brand Introduction.

Head-to-Head Comparison

Criteria	Zorb 4D (All-in-One)	Zorb 3D + ProSoft PUL (Modular)
Absorption Capacity	Up to 8× fabric weight	Up to 10× fabric weight (full unlaminated capacity)
Waterproof Protection	Embedded PU film between layers	Separate ProSoft PUL layer
Total Thickness	Thinner — no air gap between layers	Slightly thicker — separate layers plus seam allowances
Pieces to Cut	One fabric	Two or more fabrics
Sewing Complexity	Fewer seams, but all must be waterproof-sealed	More seams, but standard sewing techniques
Seam Treatment	Waterproof tape or enclosed construction required	Standard seam finishing — no sealing needed
Layer Customization	Fixed — layers are bonded at the factory	Full flexibility — choose each layer independently
Component Replacement	Replace entire fabric when any layer fails	Replace only the worn layer
Noise Level	Quieter — SilentFlex eliminates crinkle noise	Varies by Choice ProSoft PUL = Silent. Other PUL ≠ Silent.
Surface Style Options	Stay Dry, Organic Cotton	All Zorb 3D styles paired with any ProSoft PUL

About SilentFlex Technology: Our ProSoft PUL and Zorb 4D uses ECO-Thermal Bonding Technology to laminate its layers without adhesive films, which eliminates the plastic crinkle sound associated with many waterproof fabrics. This is a meaningful advantage for products worn against the body—period underwear, incontinence garments, and baby diapers—where noise affects user confidence and comfort. The modular approach can achieve quiet performance by selecting a quiet ProSoft PUL variant, but the sound characteristics depend entirely on which PUL you choose.

Which Approach Is Right for Your Project?

You want the simplest possible construction with fewest pieces to cut and sew → Zorb 4D. One fabric gives you both functions. Accept the seam-sealing requirement and the absorption trade-off in exchange for dramatically reduced construction time.

You need maximum absorption capacity (up to 10× vs 4D's up to 8×) → Zorb 3D + ProSoft PUL. Overnight cloth diapers, heavy incontinence products, and high-volume applications benefit from the full uncompromised capacity of standalone Zorb 3D.

You're manufacturing finished products at scale and production speed matters → Zorb 4D. Cutting one fabric instead of two, managing fewer components, and assembling fewer layers per unit reduces per-unit production time. Factor in the cost of waterproof seam tape when calculating total production economics.

You're a DIY maker wanting maximum design flexibility or you want to experiment with different layer combinations → Zorb 3D + ProSoft PUL. You can try different Zorb 3D weights, different PUL types, and different layer orders without committing to a pre-bonded laminate.

Noise is a primary concern for products worn under clothing → Zorb 4D CORE PUL with SilentFlex Technology provides the quietest construction. If using the modular approach, use our quiet ProSoft PUL options.

You plan to sell replacement inserts or want end users to swap absorbent cores over the product's life → Zorb 3D + ProSoft PUL. Modular construction lets you offer the waterproof shell and absorbent insert as separate components, extending product life and creating a replacement parts revenue stream.

Recommended Products by Approach

Option 1: The All-in-One Approach (Zorb 4D)

Best for those who want a streamlined process. Zorb 4D combines the absorbent core and waterproof barrier into a single fabric.

Next Step: See Zorb Families Compared to view the full lineup.
Available Variants: V1, V2, Heavy Duty, Silver, Print, REPREVE®, and FoodSAFE®.
Surface Styles: Available in Stay Dry or Organic Cotton.

Option 2: The Modular Approach (Zorb 3D + ProSoft PUL)

Best for custom projects where you want to control the weight, stretch, and feel of each layer.

Select your Zorb 3D absorbent layer: Refer to Zorb Families Compared for surface styles and Zorb Weight Classes for thickness guidance.
Select your ProSoft PUL waterproof layer: Refer to the ProSoft Brand Introduction to choose your preferred weight, stretch, and finish.
Optional Stay-Dry top layer: If using natural-fiber cores (Organic Cotton, Bamboo, Diamond), add a ProCool wicking fabric as a top sheet to keep skin dry.

FoodSAFE® Note: Both approaches are available in FoodSAFE® certified versions for food-contact applications. Zorb 4D FoodSAFE products and Zorb 3D FoodSAFE products can be paired with FoodSAFE-certified ProSoft PUL for modular food-service constructions.