ProSoft 1 mil ECO-PUL: The Complete Guide to Wazoodle's Foundation Waterproof Barrier Fabric

What ProSoft® Waterproof 1 mil ECO-PUL™

ProSoft® Waterproof 1 mil ECO-PUL™ is the standard-weight foundation waterproof barrier fabric in Wazoodle's ProSoft PUL line — a polyurethane laminate that fuses 1 mil TPU film to a polyester interlock knit base using ECO-Thermal Bonding Technology (permanent film fusion independently tested 50% stronger than competitor US-made PUL). At 155 GSM and 0.018" thickness, this construction delivers a waterproof barrier rated at more than 100× any normal use pressure while breathing at roughly the rate a resting body produces moisture vapor — replacing vinyl-coated fabrics and plastic sheeting in applications where comfort matters alongside liquid containment.

All 1 mil ECO-PUL variants share Waterproof 300X Technology (rated waterproof integrity through 300+ wash cycles) and SilentFlex Technology (quiet, fabric-like drape without plastic rustling). The lineup spans 13 variants across solid colors, printed patterns, Silver Plus antimicrobial options, HydroSHIELD hydrophobic treatment, REPREVE recycled polyester bases, FoodSAFE FDA food-contact certified options, and a Heavy Duty weight class.

Where 1 mil ECO-PUL fits: This is the most versatile starting point in the ProSoft waterproof line, with the widest variant range (13 options including solids, prints, antimicrobial, hydrophobic, recycled bases, and FDA food-contact certified). Choose 1 mil ECO-PUL when breathability, natural drape, and variant selection are priorities — cloth diapers, wet bags, menstrual products, food storage, and bag linings. For an even thinner profile, see the Lightweight ECO-PUL at 100 GSM. For thicker barrier requirements, the ProSoft line includes 2 mil and 3-layer PUL options at higher weight classes.

Every variant requires seam sealing tape over all sewn seams to maintain waterproof integrity — a universal construction requirement across all 13 variants. 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 1 mil ECO-PUL compares to CORE PUL, FoodSAFE PUL, and MediPUL, see Choosing Between ProSoft PUL Types (DF-005).

The ProSoft® Waterproof 1 mil ECO-PUL™ Lineup

ProSoft® Waterproof 1 mil ECO-PUL™ is available in 13 variants sharing the same core waterproof barrier construction but differing in base fiber, surface treatment, pattern, food-contact certification, and weight class. Ten standard-weight variants share identical core specs: 155 GSM, 0.018" thickness, waterproof barrier rated at more than 100× normal use pressure, breathability matched to resting body moisture output, 10% crosswise stretch. FoodSAFE variants share the same waterproof and breathability ratings with minor thickness variations noted below. The Heavy Duty variant diverges significantly.

Standard Polyester — Solid Colors
  • ProSoft® Waterproof 1 mil ECO-PUL™ Fabric (W-375): The foundation variant. 155 GSM, 58"–60" width, 0.018" thickness. 75% polyester / 25% polyurethane interlock knit base with ECO-Thermal Bonding Technology (permanent film fusion independently tested 50% stronger than competitor US-made PUL). Widest color selection in the lineup.
  • ProSoft® Waterproof 1 mil ECO-PUL™ Silver Fabric (W-274): Same base construction as W-375 with Silver Plus antimicrobial treatment (inhibits bacteria, fungi, and algae growth for odor control). Rated 99.5% effective after 50 wash cycles. For extended-wear applications requiring odor management between washes.
  • ProSoft® Waterproof 1 mil ECO-PUL™ Hydrophobic Fabric (W-374): Same base construction as W-375 with HydroSHIELD surface treatment (causes water to bead and roll off the fabric surface). For applications where surface water repellency matters alongside the internal waterproof barrier.
Standard Polyester — Printed Patterns
REPREVE® Recycled Polyester
FoodSAFE® Food-Contact Certified
  • ProSoft FoodSAFE® Waterproof PUL Fabric (W-396): 155 GSM, 58"–60" width, 0.020" thickness. Standard polyester base with FDA food-contact certification (21 CFR 177.1680 and 175.300) — both fabric and film sides certified safe for direct contact with all food types from freezer (-20°C) to 250°F. Customers describe a buttery-soft hand feel with no plastic smell.
  • ProSoft FoodSAFE® Waterproof PUL Print Fabric (W-512): 160 GSM, 56"–60" width, 0.020" thickness. Printed polyester base with FDA food-contact certification. Decorative patterns on food-safe waterproof construction for snack bags, bowl covers, and baby bibs where visual appeal matters alongside certified food safety.
  • ProSoft FoodSAFE® REPREVE® Waterproof PUL Fabric (W-392): 155 GSM, 58"–60" width, 0.018" thickness. REPREVE recycled polyester base (12 plastic bottles per yard) with FDA food-contact certification. The only recycled-content PUL certified for direct food contact. Combines sustainability credentials with food-safe verification.
Heavy Duty
  • ProSoft® Waterproof 1 mil ECO-PUL™ Heavy Duty Fabric (W-606): 315 GSM, 0.060" thickness, 60" width, 15% crosswise stretch. Same waterproof and breathability ratings as standard-weight variants, but double the weight and triple the thickness. For commercial-grade durability in outdoor furniture cushion barriers, commercial incontinence products, and institutional mattress protectors.
Key Concept — Heavy Duty (W-606): The weight and thickness outlier in this lineup. At 315 GSM and 0.060", it shares the same waterproof and breathability ratings as the 155 GSM standard variants but provides substantially more physical durability. If your application doesn't require that extra toughness, standard-weight variants deliver identical waterproof performance at less than half the weight.
Key Concept — FoodSAFE Variants: W-396 and W-512 measure at 0.020" thickness compared to 0.018" for standard variants. This minor difference (within ±10% manufacturing tolerance) does not affect waterproof performance or construction techniques. All FoodSAFE variants share the same waterproof and breathability ratings as standard variants.

All measurements are subject to ±10% manufacturing tolerance. Your results may vary slightly between production runs.

For film thickness and fabric type decisions across the full ProSoft line, see ProSoft PUL Construction Decisions (DF-006).

Choosing Your ProSoft® Waterproof 1 mil ECO-PUL™

ProSoft® Waterproof 1 mil ECO-PUL™ selection comes down to five decisions. All standard-weight variants share identical waterproof barrier performance (rated waterproof pressure more than 100× normal use, breathability matched to resting body moisture output, Waterproof 300X Technology durability), so the choice is about food-contact certification, treatment, surface, base fiber, and weight class.

Food-Contact & Treatment Decisions

Do you need FDA food-contact certification?
FoodSAFE variants (W-396, W-512, W-392) carry FDA certification per 21 CFR 177.1680 and 175.300 for repeated-use food storage — both fabric and film sides are tested safe for direct contact with all food types from freezer to 250°F. Choose FoodSAFE for reusable snack bags, sandwich wraps, bowl covers, lunch bag linings, and any application where the fabric contacts food directly. If your product doesn't involve food contact, standard variants perform identically on waterproofing at lower cost.

Do you need antimicrobial odor control?
Silver Plus variants (W-274, W-509, W-674) add bacterial inhibition rated 99.5% effective through 50 wash cycles. Choose Silver Plus for products worn extended periods between washes — overnight diapers, incontinence products, menstrual pad backing. If your product gets washed after every use, standard variants perform identically on waterproofing.

Do you need surface water repellency?
The HydroSHIELD variant (W-374) causes water to bead and roll off the fabric surface. Most PUL applications rely on the internal waterproof film barrier alone. Choose HydroSHIELD when the fabric surface itself faces direct water exposure — shower caps, pouch binding, applications where surface beading adds functional benefit.

Do you need recycled content verification?
REPREVE variants (W-675, W-674, W-319, W-392) use certified recycled polyester diverting 12 plastic bottles per yard. Waterproof performance matches standard polyester exactly. Choose REPREVE when sourcing policies or brand positioning require verified recycled content. The FoodSAFE REPREVE variant (W-392) combines food-contact certification with recycled content.

Surface & Weight Decisions

Solid vs. printed?
Solid color variants (W-375, W-274, W-374, W-396) offer the widest color selection at 58"–60" width. Print variants (W-510, W-509, W-530, W-319, W-512) provide decorative patterns at 56"–60" width and may require 20–40% additional yardage for pattern matching.

Standard print vs. face print?
Standard print PUL (W-510, W-509, W-319, W-512) places the waterproof film on the back with the pattern visible on the face. Face Print PUL (W-530) laminates the film onto the printed face side, leaving soft interlock on the reverse. Choose Face Print when the waterproof surface should be the outer, wipeable layer.

Standard weight vs. Heavy Duty?
Standard-weight variants (155 GSM, 0.018") suit the vast majority of applications — cloth diapers, wet bags, pad backing, food storage, bag linings. Heavy Duty (W-606, 315 GSM, 0.060") targets commercial and institutional applications requiring substantially more physical durability: outdoor furniture cushion barriers, commercial incontinence products, and items subject to heavy mechanical stress. Users report Heavy Duty withstands scratching from 90+ lb dogs.

For choosing between ECO-PUL and other ProSoft PUL types (CORE PUL, FoodSAFE, MediPUL), see Choosing Between ProSoft PUL Types (DF-005).

Working With ProSoft® Waterproof 1 mil ECO-PUL™

ProSoft® Waterproof 1 mil ECO-PUL™ requires specific machine setup and construction techniques because of its waterproof polyurethane film layer. The slippery film surface sticks to standard presser feet, every needle hole compromises the waterproof barrier, and thread choice affects whether moisture wicks through stitch points. Once you have the right setup, users consistently report the fabric is easy to cut and straightforward to sew.

Machine Setup & Sewing Techniques
  • Presser foot: Walking foot or Teflon/glide foot is essential — standard feet stick to the film, causing drag. Alternatives: sew through wax paper (tear away after), or dab machine oil on the foot.
  • Needles: Use ballpoint/jersey needles (sizes 75/11 or 80/12) — the interlock knit base requires ballpoint tips that push between yarns. Sharp needles slice yarns and enlarge needle holes, creating leak points.
  • Thread: Quality polyester thread (Tex-27 or 65/2 grade) exclusively. Cotton and rayon wick moisture through needle holes, defeating the barrier.
  • Orientation: Film side down against feed dogs — teeth grip the slippery surface while the textile face rides smoothly under the foot.
  • Cutting: Cuts cleanly without fraying — no edge finishing required. Use clips instead of pins. Mark on the textile side only.
Seam Sealing Heat-activated seam sealing tape must be applied over all sewn seams for waterproof integrity. Stitching creates needle holes through the TPU film, and seam sealing tape melts into those holes to restore the barrier. Apply tape using a warm iron or heat applicator over completed stitched seams — tape is a sealant, not a structural replacement for stitching.

Critical: Every needle hole through the polyurethane film permanently compromises waterproofing. Use clips instead of pins, plan stitching lines carefully, and seal every sewn seam with heat-activated tape.

No pre-washing required — all variants ship cut-and-sew ready. Manufacturing odor from thermal bonding dissipates after 24–72 hours of airing or a single wash-dry cycle.

Pairing ProSoft® Waterproof 1 mil ECO-PUL™ With Other Fabrics

ProSoft® Waterproof 1 mil ECO-PUL™ serves as the waterproof barrier layer in multi-layer constructions, positioned between absorbent cores and outer shells. Its thin profile minimizes bulk when layered.

Absorbent Partners (Above PUL Barrier)
  • Zorb® Original: Enclosure-required absorbent fabric for rapid liquid capture in diaper inserts and menstrual pad cores. Position between a skin-contact surface layer and the PUL barrier. For details, see Zorb® Original: The Complete Guide to Wazoodle's Foundation Absorbent Fabric.
  • Zorb® 3D Stay Dry: Stay-dry absorbent fabric that can contact skin directly, eliminating the need for a separate wicking top layer. Pairs with PUL barrier underneath. For details, see Zorb® 3D Stay Dry Dimple: The Complete Guide to Wazoodle's Premium Stay-Dry Absorbent Fabric.
  • ProECO® Organic Cotton Fleece: Natural fiber absorbent layer providing both absorbency and soft skin contact for organic product lines. Position above PUL barrier. For details, see ProECO® Organic Cotton Fleece: The Complete Guide to Wazoodle's Premium Organic Absorbent Fabric.
Surface & Shell Partners (Over or Adjacent to PUL)
  • ProCool® Performance Interlock: Moisture-wicking interlock knit for skin-contact surface layers in diaper and pad constructions. Pulls moisture away from skin into the absorbent core while PUL prevents liquid escape underneath. For details, see ProCool® Performance Interlock: The Complete Guide to Wazoodle's Versatile Moisture-Wicking Fabric.
  • Cotton flannel and cotton jersey: Common outer shell and decorative layers for cloth diapers, wet bags, and changing pads. PUL provides the waterproof barrier while cotton provides the visual and tactile surface.
Proven Layer Stacks
  • Cloth diaper cover: Outer shell fabric → ProSoft 1 mil ECO-PUL (W-375 or Silver W-274) as waterproof barrier wrapping over a separate absorbent insert.
  • Menstrual pad: Skin-contact topper (ProCool® Interlock or cotton) → absorbent core (Zorb® Original) → ProSoft 1 mil ECO-PUL (W-375 or Silver W-274) as waterproof backing. This stack is customer-validated in humanitarian menstrual kit programs worldwide.
  • Reusable wet bag: ProSoft 1 mil ECO-PUL Print (W-510 or W-319) as the complete bag shell — printed face outward, waterproof film inward. No additional layers required for basic construction.
  • Reusable food storage bag: ProSoft FoodSAFE 1 mil PUL (W-396 or FoodSAFE Print W-512) as the interior lining paired with decorative cotton exterior — food-safe film faces inward for direct food contact. FoodSAFE REPREVE (W-392) adds recycled content to the same construction.
  • Mattress/changing pad protector: Surface fabric (ProCool® terry or cotton flannel) → ProSoft 1 mil ECO-PUL (W-375) or Heavy Duty (W-606) as waterproof barrier. Heavy Duty recommended for commercial settings.
Use full product identifiers with W-### codes when ordering components for each layer position.

For complete application build guidance including layer counts, see the relevant Application Discovery articles.

ProSoft® Waterproof 1 mil ECO-PUL™ Applications

ProSoft® Waterproof 1 mil ECO-PUL™ is customer-validated across baby products, personal care, humanitarian programs, food storage, pet products, and industrial applications. Breathable waterproofing, thin profile, and chemical-free safety drive this range of use.

Cloth diapers and baby care remain the primary application — diaper covers, training pants, wet bags, changing pads, bibs, and burp cloths. The waterproof barrier holds at pressures far beyond any realistic use while breathing off body moisture instead of trapping it against skin. Professional diaper makers report reliable production and note ProSoft ECO-PUL outperforms competing PUL after repeated washing.

Menstrual and incontinence products are the second-largest category — reusable menstrual pads, postpartum products, nursing pads, bladder leakage pads, and adult incontinence underpads. Silver Plus variants (W-274, W-509, W-674) provide antimicrobial odor control (bacterial inhibition for extended-wear products). Dark brown colorways conceal staining. Humanitarian programs use this fabric at scale — Days for Girls chapters, Operation Christmas Child volunteers, and Keep Girls in School programs in Ghana produce washable menstrual kits for communities where disposable products are unavailable.

Reusable food storage and bags represent a growing category, particularly with FoodSAFE variants (W-396, W-512, W-392). Makers produce reusable snack bags, sandwich wraps, bowl covers replacing plastic wrap, sourdough banneton liners, lunch bag linings, and bread storage bags. FoodSAFE variants carry FDA food-contact certification for direct contact with all food types — customers report cheese staying fresh for six days in FoodSAFE-lined bags. Standard variants are also used for cosmetic pouches, toiletry bags, backpack linings, and travel organizers where food-contact certification is not required.
Pet products include diapers for dogs and ducks (users report exceptional wash durability for waterfowl), dog raincoats, pet bed covers, and feral cat shelter bedding. REPREVE Silver (W-674) withstands scratching from 90+ lb dogs. FoodSAFE REPREVE (W-392) is used for pet feeding mats and cage liners.

Specialty and industrial uses include outdoor TV covers, machine wash-down covers, wheelchair seating protection, shower curtains, go kart seat cushioning, and running gaiters. Professional bag makers with 7+ years describe this as their preferred PUL.

For complete application build guidance including layer counts, see the relevant Application Discovery articles.

ProSoft® Waterproof 1 mil ECO-PUL™ Certifications & Safety

ProSoft® Waterproof 1 mil ECO-PUL™ holds certifications for children's product safety, chemical-free manufacturing, and international regulatory compliance across all 13 variants. REPREVE variants additionally carry recycled content certification; FoodSAFE variants carry FDA food-contact certification.

Safety Certifications
  • CPSIA Certified: Meets Consumer Product Safety Improvement Act requirements for children's products including lead, phthalate, and flammability standards.
  • California Proposition 65 Compliant: Meets California's safe harbor levels for listed chemicals.
  • California Technical Bulletin 117 Section E: Meets furniture fire resistance standards.
  • 16 CFR Part 1611 CS 192-53: Meets federal flammability standards.
  • EU REACH SVHC Compliant: Meets European Substances of Very High Concern requirements.
  • EU RoHS 10 Compliant: Meets European Restriction of Hazardous Substances directive.
Chemical-Free Verifications
  • Forever Chemicals-Free: Verified free of PTFE, PFAS, PFOS, and PFOA.
  • BPA-Free: No bisphenol A in any component or manufacturing process.
  • Phthalate-Free: No DEHP, DBP, BBP, DINP, DIDP, or DnOP.
  • pH Neutral: Confirmed no acidic or alkaline residues per independent lab testing.
  • Hypoallergenic: Latex-free, nanoparticle-free, vegan construction.
FoodSAFE® Food-Contact Certification (W-396, W-512, W-392 Only)
  • FDA 21 CFR 177.1680: Polyurethane resins certified for repeated-use food contact.
  • FDA 21 CFR 175.300: Resinous and polymeric coatings certified for food-contact surfaces.
  • FDA 21 CFR 175.320 (W-392): Additional resinous and polymeric coating validation.
  • Both-Side Certification: Fabric side and polyurethane film side both tested safe for direct food contact with all food types (baked goods, dairy, fats, acidic foods, beverages) from frozen storage (-20°C) to 250°F.

Fabric vs. Finished Product: These certifications apply to the ProSoft 1 mil ECO-PUL fabric as manufactured and sold by Wazoodle. Finished products you make from this fabric may require separate testing and certification depending on your jurisdiction and product category. The fabric's certifications do not automatically transfer to your finished goods.

For what these certifications mean and how they apply to different product categories, see Understanding Wazoodle Fabric Certifications & Safety Standards.

For how FDA food-contact certification works across the full FoodSAFE product line, see ProSoft FoodSAFE PUL: The Complete Guide to FDA Food-Contact Certified Waterproof Fabrics.

Caring for ProSoft® Waterproof 1 mil ECO-PUL™

ProSoft® Waterproof 1 mil ECO-PUL™ maintains its Waterproof 300X Technology (300+ wash cycle durability) when care protocols protect the polyurethane film from chemical degradation and heat damage. The primary threats to longevity are fabric softeners, chlorine bleach, and excessive dryer heat — each can permanently destroy the waterproof barrier.

Washing

Hot water is safe (rated to 145–165°F), though warm water extends film lifespan. Use zero-residue liquid detergent. Add an extra rinse cycle to remove detergent residues that accumulate on and degrade the polyurethane film over time. Protect the film side during washing when possible — construction methods that shield the waterproof layer from direct agitation extend product life.

Drying

Low to medium heat only — never exceed 130°F (50°C). High heat causes polyurethane breakdown that appears as stiffening, cracking, or delamination. Line drying is always safe.

Manufacturing odor

New fabric may have a noticeable smell from the thermal bonding process. This is not harmful and dissipates within 24–72 hours of airing in a ventilated space, or after a single wash-dry cycle.

Substances that permanently destroy waterproofing: Fabric softeners coat the polyurethane film and eliminate both waterproofing and breathability — damage is irreversible. Chlorine bleach causes delamination. Vinegar and baking soda break down the laminate bond. Dryer sheets coat the film identically to liquid softeners. Non-chlorine oxygen bleach is acceptable sparingly if needed.

For complete ProSoft PUL care protocols including sanitization options and troubleshooting, see ProSoft PUL Care Guide.

ProSoft® Waterproof 1 mil ECO-PUL™ Technical Specifications

ProSoft® Waterproof 1 mil ECO-PUL™ variants share a common waterproof barrier platform with identical hydrostatic pressure and breathability ratings. The key specification differences are weight, thickness, stretch, and width — with Heavy Duty (W-606) as the clear outlier.

FoodSAFE variants W-396 and W-512 show minor thickness and weight variations from the standard platform.

Specification Standard Weight (10 variants) FoodSAFE (W-396, W-512) Heavy Duty (W-606)
Weight 155 GSM / 4.6 oz/sq yd 155–160 GSM / 4.6 oz/sq yd 315 GSM / 9.3 oz/sq yd
Thickness 0.018" ± 10% 0.020" ± 10% 0.060" ± 10%
Width 58"–60" (prints: 56"–60") 58"–60" (W-512: 56"–60") 60"
Crosswise Stretch 10% 10% 15%
Lengthwise Stretch Minimal Minimal Minimal
Shrinkage Minimal (both directions) Minimal (both directions) Minimal (both directions)
Fiber Composition 75% polyester / 25% PU 75% polyester / 25% PU 75% polyester / 25% PU
Hydrostatic Pressure 225 psi (~158,000 mm) 225 psi (~158,000 mm) 225 psi (~158,000 mm)
Breathability (MVTR) 850 g/m²/24h 850 g/m²/24h 850 g/m²/24h
Burst Strength 152 psi 152 psi 152 psi
UPF Rating 25–35 (color dependent) 25–35 (color dependent) 25–35 (color dependent)
pH 7.4 (neutral) 7.4 (neutral) 7.4 (neutral)
FDA Food Contact — 21 CFR 177.1680, 175.300 —

All measurements are subject to ±10% manufacturing tolerance. REPREVE variants (W-675, W-674, W-319, W-392) use recycled polyester with identical performance ratings.

FoodSAFE REPREVE (W-392) shares 0.018" thickness with the standard platform. ASTM test methods: MVTR per ASTM E 96, hydrostatic pressure per ASTM D 751, burst strength per ASTM D3786.

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