ProSoft MediPUL: The Complete Guide to Wazoodle's Medical-Grade Level 4 Barrier Fabric

What ProSoft MediPUL® Is

ProSoft MediPUL® is a medical-grade waterproof barrier fabric in Wazoodle's ProSoft PUL line — a polyurethane laminate that bonds TPU film to a fabric base using ECO-Thermal Bonding Technology (permanent film fusion independently tested 50% stronger than competitor US-made PUL) and achieves ANSI/AAMI PB70 Level 4 certification, the highest barrier protection standard for surgical gowns and medical textiles. Level 4 certification means the fabric passes both synthetic blood penetration resistance (ASTM F1670-B) and viral penetration resistance (ASTM F1671-B) testing for bloodborne pathogen protection.

Where MediPUL fits: MediPUL uses the same ECO-PUL surface-laminated construction as the standard ECO-PUL line, but with Level 4 medical barrier certification, commercial laundering durability (300+ cycles at 160–165°F), and organic cotton base options for clinical skin contact. Choose MediPUL when healthcare facility compliance, bloodborne pathogen resistance, or commercial laundering protocols are required. For consumer-grade waterproofing without medical certification needs, standard ECO-PUL provides the same breathability at lower cost.

All 6 MediPUL variants share a waterproof barrier rated at more than 100× any normal use pressure with breathability matched to resting body moisture output, Waterproof 300X Technology (rated integrity through 300+ wash cycles), and SilentFlex Technology (quiet operation). The lineup spans 3 weight classes across polyester and organic cotton bases, with Silver Plus antimicrobial options in each. Every variant requires seam sealing tape over all sewn seams to maintain waterproof integrity.

Made in USA by AKAS Tex. CPSIA certified for children's products. Forever Chemicals-Free verified (no PFAS, PFOA, PFOS, BPA, or phthalates).

For how MediPUL compares to ECO-PUL, CORE PUL, and FoodSAFE PUL, see Choosing Between ProSoft PUL Types (DF-005).

The ProSoft MediPUL® Lineup

ProSoft MediPUL® is available in 6 variants organized across 3 weight classes. All share Level 4 ANSI/AAMI PB70 certification, the same waterproof barrier, breathability, and burst strength. They differ in base fiber, weight, stretch behavior, and antimicrobial treatment.

Standard Polyester — 160 GSM

ProSoft MediPUL® Level 4 Barrier Fabric (W-561): The lightest MediPUL variant. 160 GSM, 58"–60" width, 0.018" thickness. 70% polyester / 30% polyurethane interlock knit base with 10% crosswise stretch. **ECO-Thermal Bonding Technology** (permanent film fusion independently tested 50% stronger than competitor US-made PUL). Soft hand feel comparable to high-end PUL alternatives.
ProSoft MediPUL® Level 4 Barrier Silver Fabric (W-569): Same base as W-561 with **Silver Plus antimicrobial treatment** (inhibits bacteria, fungi, and algae growth, rated 99.9% effective when moisture-activated). For extended-wear applications requiring odor management — incontinence products, overnight medical garments.

Organic Cotton No-Stretch — 240 GSM

ProSoft MediPUL® Organic Cotton No-Stretch Level 4 Barrier Fabric (W-581): 240 GSM medium weight with 70% organic cotton / 30% polyurethane and minimal stretch in both directions. 58"–60" width, 0.019" thickness. US Cotton Trust Protocol verified organic cotton provides hypoallergenic skin contact. 1–2% shrinkage after first wash. UPF 50+.
ProSoft MediPUL® Organic Cotton No-Stretch Level 4 Barrier Silver Fabric (W-347): Same organic cotton no-stretch base as W-581 with \*\*Silver Plus antimicrobial treatment\*\*. 52"–60" width. For medical applications requiring dimensional stability, organic fiber, and odor control.

Organic Cotton Standard — 255 GSM

ProSoft MediPUL® Organic Cotton Level 4 Barrier Fabric (W-635): The heaviest MediPUL variant. 255 GSM, 58"–60" width, 0.032" thickness. 70% organic cotton / 30% polyurethane with 10% crosswise stretch (unlike the No-Stretch organic cotton variants). 1–2% shrinkage. UPF 50+. Food-safe tested.
ProSoft MediPUL® Organic Cotton Level 4 Barrier Silver Fabric (W-673): Same organic cotton base as W-635 with \*\*Silver Plus antimicrobial treatment\*\*. For applications requiring the heaviest barrier weight, organic fiber, stretch flexibility, and antimicrobial odor control.

All measurements are subject to ±10% manufacturing tolerance. Your results may vary between production runs.
For construction and base fiber decisions across the full ProSoft line, see ProSoft PUL Construction Decisions.

Choosing Your ProSoft MediPUL®

ProSoft MediPUL® variant selection involves three decisions — all six variants share identical Level 4 barrier certification and waterproof performance.

Base Fiber & Weight

Do you need organic cotton?
The four organic cotton variants (W-581, W-347, W-635, W-673) provide hypoallergenic, bio-based fiber for direct patient skin contact. Choose organic cotton for surgical gowns, patient underpads, and applications where chemical-free fiber processing matters. The two polyester variants (W-561, W-569) are lighter at 160 GSM and offer the most economical Level 4 option.

Which weight class?
The 160 GSM polyester variants are lightest for garment applications. The 240 GSM organic cotton no-stretch variants provide dimensional stability for fitted covers and underpads. The 255 GSM organic cotton variants are heaviest and thickest (0.032") for maximum barrier substance — and are food-safe tested.

Stretch & Antimicrobial

Do you need no-stretch?
The No-Stretch organic cotton variants (W-581, W-347) provide minimal stretch in both directions for applications requiring consistent dimensions — examination table covers, fitted mattress protectors, equipment covers. All other variants provide 10% crosswise stretch for comfort and fit flexibility.

Do you need antimicrobial odor control?
Silver Plus variants (W-569, W-347, W-673) add bacterial inhibition rated 99.9% effective for extended-wear medical applications. Choose Silver for incontinence products, overnight garments, and any application worn between wash cycles. If products get washed after each use, the standard variants perform identically on barrier protection.

Users who have worked with MediPUL report quality comparable to premium PUL alternatives, with soft hand feel and textile-like drape rather than plastic stiffness.

Working With ProSoft MediPUL®

ProSoft MediPUL® requires the same core PUL construction techniques as the ECO-PUL line, with attention to the surface-laminated film layer. The organic cotton variants are heavier and require appropriate machine capacity for multi-layer construction.

Machine Setup & Sewing Techniques

Presser foot: A Teflon/glide foot or walking foot prevents the PUL film surface from sticking. Walking foot recommended for the heavier organic cotton variants. Alternatives: sew through wax paper, or dab sewing machine oil on the foot.
Needles: Use ballpoint/jersey needles (sizes 70/10 to 90/14 depending on weight class) for the knit base. Sharp needles slice yarns and enlarge holes, creating leak points.
Thread: Use quality polyester thread (Tex-27 or 65/2 grade). Cotton and rayon threads wick moisture through needle holes.
Stitch length: 3.0–3.5 mm provides secure seams without excessive film perforation.
Pinning: Pin only within seam allowances — needle holes permanently puncture the waterproof film. Use clips, mini clothespins, or pattern weights where possible.

Seam Sealing Heat-activated seam sealing tape must be applied over all sewn seams. Stitching creates needle holes through the TPU film, and the tape melts into those holes to restore the waterproof barrier. Apply with warm iron on the fabric side only — never iron the polyurethane film side directly.

Critical: Every needle hole through the polyurethane film permanently compromises waterproofing. Pin only in seam allowances, plan stitching lines carefully, and seal every sewn seam with heat-activated tape.

No pre-washing is required — all variants ship cut-and-sew ready. Organic cotton variants will shrink 1–2% after first wash; factor this into pattern cutting if pre-washing is not planned. Manufacturing odor from thermal bonding dissipates after a wash-dry cycle or 1–14 days of airing.

Pairing ProSoft MediPUL® With Other Fabrics

ProSoft MediPUL® serves as the waterproof barrier layer in multi-layer medical and healthcare constructions, positioned between absorbent cores and patient-facing surfaces.

Absorbent Partners (Above MediPUL Barrier)

Zorb® Original: Enclosure-required absorbent fabric for rapid liquid capture in incontinence pads and medical underpads. Position between a skin-contact surface and the MediPUL barrier. For details, see Zorb® Original: The Complete Guide to Wazoodle's Foundation Absorbent Fabric.
Zorb® 3D Stay Dry: Stay-dry absorbent that can contact skin directly, eliminating a separate wicking surface layer. For details, see Zorb® 3D Stay Dry Dimple: The Complete Guide to Wazoodle's Premium Stay-Dry Absorbent Fabric.

Surface Partners (Patient-Facing Layers)

ProCool® Performance Interlock: Moisture-wicking interlock for skin-contact surface layers. For details, see ProCool® Performance Interlock: The Complete Guide to Wazoodle's Versatile Moisture-Wicking Fabric.
ProECO® Organic Cotton: Natural fiber surface layers for products requiring organic certification throughout. For details, see ProECO® Organic Cotton Fleece: The Complete Guide to Wazoodle's Premium Organic Cotton Fabric.
Cotton flannel: Common patient-facing surface in hospice bed pads and charitable underpad construction.

Proven Layer Stacks

Hospice bed pad: Cotton flannel surface → batting or Zorb® absorbent core → ProSoft MediPUL (W-561 or Silver W-569) as waterproof backing. Charitable sewing groups commonly use this three-layer construction for donated patient bed protection.
Medical incontinence underpad: ProCool® surface → absorbent core (Zorb® Original) → ProSoft MediPUL Organic Cotton Silver (W-347 or W-673) as waterproof barrier with antimicrobial odor control and hypoallergenic skin contact.
Surgical gown barrier: Outer shell fabric → ProSoft MediPUL (any variant) as Level 4 barrier layer → inner comfort lining. Weight class selection depends on garment drape requirements.

ProSoft MediPUL® Applications

ProSoft MediPUL® is validated across medical, institutional, charitable, and specialty applications. The Level 4 certification and commercial laundering durability distinguish MediPUL from consumer-grade PUL in healthcare settings.

Surgical and isolation gowns represent the primary medical application — Level 4 ANSI/AAMI PB70 certification provides documented bloodborne pathogen protection for operating rooms and infectious disease control. Breathability matched to resting body moisture output prevents heat buildup during extended procedures.

Patient care products include medical underpads, examination table covers, mattress protectors, patient bibs, and positioning aids. Hospice sewing groups and church community projects construct washable bed pads using MediPUL as the waterproof backing with cotton flannel facing and batting absorbent cores — addressing incontinence needs in end-of-life care settings.

Incontinence products span adult underpads, diaper covers for disabled adults, bladder leak undergarments, and bed protection. Silver Plus variants provide antimicrobial odor control for extended-wear products.

Specialty and non-medical uses validated by customers include outdoor protective covers for electronics (soundbars, TV screens), cloth diaper covers for special needs children requiring medical-grade protection, dog bed waterproof layers, dog raincoats, changing mats, diaper bag linings, and wet bags. Users report MediPUL quality comparable to premium PUL alternatives when standard sources are unavailable.

ProSoft MediPUL® Certifications & Safety

ProSoft MediPUL® holds medical-grade barrier certifications alongside standard safety and chemical-free verifications across all 6 variants.

Medical Barrier Certifications

ANSI/AAMI PB70 Level 4: Highest barrier protection standard for surgical gowns.
ASTM F1670-B: Passes synthetic blood penetration resistance testing.
ASTM F1671-B: Passes viral penetration resistance testing for bloodborne pathogen protection.

Safety Certifications

CPSIA Certified: Meets Consumer Product Safety Improvement Act requirements for children's products.
California Proposition 65 Compliant: Meets California's safe harbor levels.
16 CFR Part 1611 CS 192-53: Meets federal flammability standards.
EU REACH SVHC Compliant and EU RoHS 10 Compliant.

Chemical-Free Verifications

Forever Chemicals-Free: Verified free of PTFE, PFAS, PFOS, and PFOA.
BPA-Free, Phthalate-Free, Lead-Free: No restricted substances.
pH Neutral: Confirmed no acidic or alkaline residues per independent lab testing.
Hypoallergenic: Latex-free, vegan construction.
US Cotton Trust Protocol (organic cotton variants): Verified organic fiber sourcing.

Fabric vs. Finished Product: These certifications apply to the ProSoft MediPUL fabric as manufactured and sold by Wazoodle. Finished medical products you make from this fabric may require separate testing, certification, and regulatory approval depending on your jurisdiction, product category, and intended clinical use.

For what these certifications mean, see Understanding Wazoodle Fabric Certifications & Safety Standards.

Caring for ProSoft MediPUL®

ProSoft MediPUL® maintains its rated 300+ wash cycle performance under commercial laundering protocols when care guidelines protect the polyurethane film.

Washing

Hot water is safe and expected for medical sanitation — up to 165°F (75°C). Use zero-residue liquid detergent with an extra rinse cycle. Compatible with medical disinfectants used in healthcare facility laundering. Non-chlorine oxygen bleach is acceptable sparingly.

Drying

Medium heat only — never exceed 130°F (50°C). High heat damages the TPU film and can cause shrinkage that appears as delamination.

Avoid completely

Fabric softeners (permanently destroy waterproofing, breathability, and antimicrobial function), chlorine bleach (causes delamination), vinegar and baking soda (break down the laminate bond), dryer sheets (coat the film).

ProSoft MediPUL® Technical Specifications

ProSoft MediPUL® variants share identical Level 4 barrier performance but differ in weight, base fiber, stretch, and thickness across 3 weight classes.

Specification	Polyester (W-561, W-569)	OC No-Stretch (W-581, W-347)	OC Standard (W-635, W-673)
Weight	160 GSM / 4.7 oz/sq yd	240 GSM / 7.1 oz/sq yd	255 GSM / 7.5 oz/sq yd
Thickness	0.018" ± 10%	0.019" ± 10%	0.032" ± 10%
Fiber Composition	70% polyester / 30% PU	70% organic cotton / 30% PU	70% organic cotton / 30% PU
Width	58"–60"	52"–60" (Silver) / 58"–60"	58"–60"
Crosswise Stretch	10%	Minimal	10%
Shrinkage	Minimal	1–2%	1–2%
UPF Rating	25–35	50+	50+

All variants: 225 psi hydrostatic pressure (~158,000 mm), 850 g/m²/24h MVTR breathability, 152 psi burst strength, Level 4 ANSI/AAMI PB70, 300+ wash cycles, pH 7.4 neutral, coefficient of friction 0.26–1.9, color fastness 4.5. All measurements ±10% manufacturing tolerance. ASTM test methods: MVTR per ASTM E 96, hydrostatic pressure per ASTM D 751, burst strength per ASTM D3786, barrier testing per ASTM F1670-B and F1671-B.