What is ProSoft? The Complete Guide to Waterproof PUL Fabrics

What ProSoft PUL Is and What Problem It Solves

ProSoft PUL is AKAS Tex's waterproof fabric line — breathable polyurethane laminate (PUL) engineered to provide complete liquid barrier protection while maintaining comfort, drape, and safety. ProSoft PUL fabrics solve a problem that vinyl, rubber, and plastic sheeting cannot: reliable waterproofing that breathes, stays silent, washes 300+ times, and contains no harmful chemicals.

Traditional waterproofing traps heat, creates noise, contains harmful chemicals, and breaks down after repeated washing. ProSoft PUL maintains its waterproof barrier through 300+ wash cycles while feeling and draping like regular fabric — because the barrier is created through ECO-Thermal Bonding Technology (solvent-free permanent film fusion), not chemical adhesives that degrade over time.

What separates ProSoft PUL from imported and adhesive-bonded PUL is independently tested performance. ProSoft's thermal bond is rated 50% stronger than competitor US-made PUL per independent ASTM D-751 testing. That bond strength is the foundation for five performance advantages — Permanent Bond, Breathable Barrier, Silent & Soft, 300+ Wash Durability, and Chemical-Free Safety — that define ProSoft's position across every product in the line.

Every ProSoft PUL fabric is manufactured in the USA, carries CPSIA certification for children's product safety, and is verified Forever Chemicals-Free.

Key Concept — Waterproof vs Water-Resistant: Waterproof means complete liquid barrier — not water resistance, which only delays penetration. ProSoft PUL holds at pressures more than 100× what any normal use creates — sitting, lying, pressing, squeezing — while still allowing your body's moisture vapor to pass through the barrier instead of being trapped against skin.

Critical Care Requirement: Never wash ProSoft PUL fabrics with fabric softeners, chlorine bleach, vinegar, or baking soda. These substances permanently destroy the waterproof barrier and breathability across all ProSoft PUL types. Dry medium heat only (under 130°F). This applies to every product in the ProSoft line without exception.

ProSoft PUL Performance: Five Pillars That Separate ProSoft from Imported PUL

ProSoft PUL performance is built on five engineering pillars. Each pillar represents a measurable advantage over adhesive-bonded PUL — and each directly affects how the fabric performs in your finished products. These five pillars apply across all ProSoft PUL families (ECO-PUL, CORE PUL, FoodSAFE PUL, and MediPUL).

1. Permanent Thermal Bond

ProSoft ECO-Thermal Bonding Technology (solvent-free permanent film fusion) creates a bond independently tested at 50% stronger than competitor US-made PUL per ASTM D-751 hydrostatic testing. The bond cannot peel, crack, or delaminate — eliminating the #1 failure mode in PUL products. When customers report PUL that is "peeling" or "cracking" after a few months of use, they are describing adhesive bond failure — the failure mode that ProSoft's thermal bond eliminates.

2. Breathable Waterproof Barrier

ProSoft PUL blocks all liquid while allowing your body's moisture vapor to pass through the waterproof membrane. Body heat and perspiration vapor escape instead of being trapped against skin — preventing the heat buildup, sweat rash, and clammy discomfort that vinyl and plastic barriers cause. Vinyl and plastic sheeting have zero breathability. ProSoft PUL breathes at roughly the rate a resting body produces moisture vapor, making it comfortable for extended wear, sleep, and skin-contact applications.

3. Silent & Soft (SilentFlex Technology)

ProSoft SilentFlex Technology (crinkle-free fabric drape) eliminates the plastic rustling noise characteristic of traditional PUL. ProSoft PUL drapes, folds, and moves like regular fabric — critical for nighttime diaper covers where crinkle wakes a sleeping baby, incontinence products where discretion matters, and garments or bedding where plastic sounds are unacceptable.

4. 300+ Wash Durability (Waterproof 300X Technology)

ProSoft Waterproof 300X Technology (wash-durable waterproof integrity) maintains the waterproof barrier through 300+ wash cycles per manufacturer testing. The independently verified 50% stronger bond directly predicts wash longevity — a stronger bond withstands more cumulative wash stress before any degradation. Adhesive-bonded PUL typically begins delaminating within 30–100 wash cycles as the adhesive layer progressively weakens.

5. Chemical-Free Safety

ProSoft PUL is manufactured using solvent-free processes and verified Forever Chemicals-Free — no PFAS, PFOA, PFOS, BPA, phthalates, lead, dioxins, heavy metals, or fluorocarbons. CPSIA certified for children's products. California Proposition 65 compliant. pH neutral per independent lab testing. The waterproofing is entirely physical — no chemical shortcuts required to achieve barrier performance.

For detailed explanations of how each technology works, see the individual ProSoft Technology Discovery articles.

The ProSoft PUL Product Landscape

ProSoft PUL encompasses over 70 fabric products organized across four product families. Each family is built for specific performance requirements — understanding which family fits your project is the first step toward choosing the right fabric.

ProSoft PUL Product Families

ECO-PUL (Standard Waterproof): The foundation of the ProSoft line. Solvent-free thermally bonded PUL available in 1 mil and 2 mil film thicknesses across polyester, organic cotton, bamboo, and recycled polyester bases. Over 40 fabric options including solid colors, prints, Silver Plus antimicrobial, HydroSHIELD hydrophobic, Stretch-FIT, and REPREVE recycled content variants. Covers the broadest range of applications from cloth diapers to wet bags to mattress protectors.
CORE PUL (Embedded Barrier): Three-layer construction that embeds the waterproof film between two fabric layers — protecting the barrier from surface abrasion and extending product lifespan. Available in 8 constructions from lightweight (180 GSM) to ultra-heavyweight all-in-one systems (685 GSM). Choose CORE PUL when maximum wash durability matters — commercial laundering, institutional use, daycare programs.
FoodSAFE PUL (FDA Food-Contact Certified): FDA-certified for direct food contact per 21 CFR 177.1680 and 175.300. The only PUL fabrics tested safe for repeated-use food storage across all food types from freezer to moderate heat. Both fabric side and film side are certified safe. Available in 16 options across polyester, organic cotton, bamboo, and recycled polyester bases.
MediPUL (Medical Grade, Level 4 Barrier): Medical-grade PUL meeting ANSI/AAMI PB70 Level 4 barrier standards — the highest surgical barrier certification. Passes synthetic blood and viral penetration testing. Available in standard MediPUL (6 options) and MediCORE PUL with embedded barrier (4 options including absorbent variants).

Within these families, ProSoft PUL fabrics vary across four construction dimensions: film thickness (1 mil standard or 2 mil heavy duty), base fiber (polyester, organic cotton, bamboo viscose, or REPREVE recycled polyester), fabric type (interlock, jersey, fleece, sherpa, loop terry, twill, foam, or mesh), and specialty variants (Silver Plus antimicrobial, Stretch-FIT lycra, HydroSHIELD hydrophobic, printed patterns).

For guidance on choosing between PUL families, see ProSoft PUL Types: ECO-PUL vs CORE PUL vs FoodSAFE PUL vs MediPUL. For guidance on film thickness, base fiber, and fabric type decisions, see ProSoft PUL Construction Types.

How ProSoft PUL Compares: Thermal Bond vs Adhesive Bond

ProSoft PUL uses thermal bonding. Most imported PUL and some domestic PUL uses adhesive bonding. This single manufacturing difference determines wash durability, noise, flexibility, and long-term waterproof reliability.

ProSoft ECO-Thermal Bond

Bond strength: Independently tested 50% stronger than competitor US-made PUL (ASTM D-751)
Wash durability: 300+ cycles — bond does not weaken progressively
Noise: Silent — SilentFlex Technology, no rigid adhesive layer
Flexibility: Full fabric drape — thickness comes from film only, not bonding chemicals
Safety: Solvent-free process, independently verified Forever Chemicals-Free

Adhesive-Bonded PUL (Imported and Some Domestic)

Bond strength: Lower per independent testing — adhesive is the weak link
Wash durability: Typically 30–100 cycles before delamination begins
Noise: Adhesive layer creates stiffness and plastic rustling
Flexibility: Adhesive adds rigidity — stiffer hand feel, less natural drape
Safety: Solvent-based manufacturing — chemical content often undisclosed

Key Concept — Delamination Is How PUL Fails: PUL doesn't fail because the film develops holes. PUL fails when the bond between film and fabric gives way — the film peels, cracks, or separates. Every wash cycle tests that bond. A stronger bond means more wash cycles before any degradation begins. When a customer reports their PUL is "peeling" or "flaking," they're describing adhesive bond failure.

ProSoft PUL Key Technologies

ProSoft PUL performance comes from five proprietary technologies developed by AKAS Tex. Each technology is named below with its performance outcome — for detailed explanations of how each technology works, see the individual ProSoft Technology Discovery articles.

ProSoft ECO-Thermal Bonding Technology — solvent-free permanent film fusion, independently tested 50% stronger than competitor PUL
ProSoft CORE PUL Technology — embedded barrier construction that shields the waterproof membrane from surface abrasion and extends durability
ProSoft SilentFlex Technology — crinkle-free fabric drape for discreet and comfortable applications
ProSoft TPU Barrier Fusion Technology — permanent film-to-fabric bond that cannot wash out or peel away, the durability foundation for 300+ wash performance
ProSoft Waterproof 300X Technology — maintained waterproof integrity through 300+ wash cycles for commercial and institutional reusable product applications

How to Choose ProSoft PUL: Navigating Product Options

Selecting the right ProSoft PUL fabric involves two decisions: which PUL family matches your project's requirements, and which construction fits your specific needs.

Start with your project's non-negotiable requirement:

General waterproofing (diapers, wet bags, mattress protectors) → Start with ECO-PUL
Maximum wash durability (commercial, institutional, daycare) → Evaluate CORE PUL
Food contact (storage bags, bowl covers, lunch linings) → FoodSAFE PUL required
Healthcare and pathogen barrier (surgical gowns, medical underpads) → MediPUL required
Odor control (incontinence, extended-wear products) → Add Silver Plus antimicrobial to your chosen family
Body-contour fit (fitted covers, underwear-style products) → Add Stretch-FIT to your chosen family

For detailed comparison and decision paths, see ProSoft PUL Types: ECO-PUL vs CORE PUL vs FoodSAFE PUL vs MediPUL. For construction-level decisions, see ProSoft PUL Construction Types.

Working with ProSoft PUL: What Makers Need to Know

ProSoft PUL waterproof performance depends on maintaining the integrity of the polyurethane film through every stage of construction. The fabric itself is waterproof — but every needle hole, pin puncture, and unsealed seam is a potential leak point.

Pins create permanent holes. Unlike woven fabrics where pin holes close, every pin pushed through PUL film creates a permanent puncture that cannot self-heal. Use sewing clips instead of pins to preserve waterproof integrity.

Every needle penetration matters. Each stitch through the PUL layer is a potential leak point. Minimize unnecessary needle holes through thoughtful seam planning and avoiding ripping out and re-sewing.

Seams are not waterproof unless sealed. ProSoft PUL fabric provides a waterproof barrier, but stitch holes do not seal themselves. Seam sealing is the maker's responsibility for true waterproof integrity. Products that leak only at seams have a seam sealing issue, not a fabric issue.

Know your film side. PUL has a smooth film side (waterproof barrier) and a textile/knit side. Identify which side is which before cutting. No heat on the film side — direct heat contact damages or destroys the polyurethane film.

For complete construction guidance for specific ProSoft PUL products, see the relevant Product Journey articles.

ProSoft PUL Common Applications

ProSoft PUL serves any application requiring a durable, breathable, washable waterproof barrier. Primary application areas include:

Baby and child care — cloth diaper covers, changing pads, bibs, burp cloths, training pants, wet bags
Hygiene and personal care — reusable menstrual pads, period underwear, nursing pads, incontinence products
Home essentials — mattress protectors, furniture covers, pet bed liners, crib sheets, pillow protectors
Food storage — reusable sandwich bags, bowl covers, lunch bag linings, breast milk storage (FoodSAFE PUL required)
Healthcare and medical — surgical gowns, isolation gowns, patient underpads, examination table covers (MediPUL required)
Pet care — pet beds, cage liners, training pads, waterproof pet outerwear

For detailed fabric recommendations for specific applications, see the relevant Application Discovery articles.

ProSoft PUL Certifications and Safety Standards

ProSoft PUL fabrics carry consistent safety certifications across the product line:

CPSIA Certified — meets Consumer Product Safety Improvement Act requirements for children's products
Forever Chemicals-Free — verified free of PFAS, PFOS, PFOA, BPA, phthalates, lead, dioxins, heavy metals, and fluorocarbons
California Proposition 65 Compliant — no materials under scope
Made in USA — manufactured in American mills under EPA and OSHA standards
pH neutral — per independent lab testing
Burst strength rated at more than 3× industry requirements per independent testing (ASTM D3786)

Specific product families carry additional certifications: FoodSAFE PUL meets FDA food contact regulations (21 CFR 177.1680 and 175.300), and MediPUL meets ANSI/AAMI PB70 Level 4 surgical barrier standards. Silver Plus antimicrobial variants are verified 99.5% effective against bacteria and fungi.

All fabric specifications may vary ±10% due to textile industry manufacturing standards. Specific certifications apply to specific products — verify certification status on individual product pages.

Fabric vs. Finished Product: CPSIA certification of the fabric component does not automatically certify your finished product. Depending on how your product is constructed, independent CPSIA testing of the finished item may also be required.

For detailed information on what these certifications mean and require, see Certifications, Chemical Safety & Compliance Standards.

Where ProSoft PUL Fits in the Wazoodle Ecosystem

ProSoft PUL is the waterproofing specialist within the Wazoodle fabric ecosystem. When your project requires a liquid barrier, ProSoft is the starting point.

Brand Routing: Choose ProSoft when your fabric's primary job is blocking liquid. Choose Zorb when you need absorption and liquid retention. Choose ProCool when you need moisture wicking and transfer away from skin without retention. Many reusable products combine two or all three brands in a layered system — for example, a ProCool wicking topsheet, Zorb absorbent core, and ProSoft PUL waterproof backing.