ProSoft Lightweight ECO-PUL: The Complete Guide to Wazoodle's Lightest Waterproof Barrier Fabric

What ProSoft® Lightweight ECO-PUL™

ProSoft® Lightweight ECO-PUL™ is the thinnest, lightest waterproof barrier fabric in Wazoodle's ProSoft PUL line — a polyurethane laminate that bonds 1 mil TPU film to a lightweight polyester knit base using ECO-Thermal Bonding Technology (permanent film fusion independently tested 50% stronger than competitor US-made PUL).

At 100 GSM and 0.013" 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 — the same waterproof and breathability ratings as the standard-weight 1 mil ECO-PUL at 35% less weight and 28% less thickness.

Where Lightweight ECO-PUL fits: This is the minimal-bulk option in the ProSoft waterproof line with 4 variants including standard, recycled, and FDA food-contact certified options. Choose Lightweight ECO-PUL when thin profile matters most — wallet card slots, makeup bag linings, garment gussets, layered pad constructions, reusable food storage bags, and any application where standard PUL adds unwanted thickness. For the widest variant selection and heavier hand feel, see the standard-weight 1 mil ECO-PUL at 155 GSM. For a thicker barrier, see the 2 mil ECO-PUL at 180 GSM.

All variants share Waterproof 300X Technology (rated waterproof integrity through 300+ wash cycles) and SilentFlex Technology (quiet operation without plastic rustling). Every variant requires seam sealing tape over all sewn seams to maintain waterproof integrity at stitch points.

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

The ProSoft® Lightweight ECO-PUL™ Lineup

ProSoft® Lightweight ECO-PUL™ is available in 4 variants sharing identical waterproof barrier specifications. All four are 100 GSM, 0.013" thick, with waterproof barrier rated at more than 100× normal use pressure, breathability matched to resting body moisture output, and 10% crosswise stretch. They differ in base fiber, food-contact certification, and recycled content.

Standard Polyester

ProSoft® Lightweight Waterproof ECO-PUL™ Fabric (W-579): Standard polyester base. 100 GSM, 53"–60" width, 0.013" thickness. 60% polyester / 40% polyurethane with **ECO-Thermal Bonding Technology** (permanent film fusion independently tested 50% stronger than competitor US-made PUL). The widest width range in the Lightweight lineup.

REPREVE® Recycled Polyester

ProSoft® Lightweight REPREVE® Waterproof ECO-PUL™ Fabric (W-288): Recycled polyester base containing 10 post-consumer plastic bottles per yard. 58"–60" width. Same waterproof and breathability specs as W-579. This variant is also food-safe certified on both sides, validated from frozen storage (-20°C) to hot contact (250°F). Recycled fiber performs identically to virgin polyester in durability and wash testing.

FoodSAFE® Food-Contact Certified

ProSoft FoodSAFE® Lightweight Waterproof PUL Fabric (W-455): Standard polyester base with FDA food-contact certification (21 CFR 177.1680 and 175.300). 100 GSM, 0.013" thickness. Both fabric and film sides certified safe for direct contact with all food types from freezer (-20°C) to 250°F. The lightest-weight food-contact certified PUL in the ProSoft line for minimal-bulk food storage applications.
ProSoft FoodSAFE® REPREVE® Lightweight Waterproof PUL Fabric (W-287): Recycled polyester base (8 post-consumer plastic bottles per yard) with FDA food-contact certification (21 CFR 177.1680 and 175.300). 58"–60" width. The only recycled-content lightweight PUL with formal FoodSAFE® branding and full FDA documentation. Combines recycled content sustainability with certified food-contact safety at the thinnest available profile.

Key Concept — Food-Safe Options in This Lineup: Three of the four Lightweight variants carry food-safe certification: W-288 (REPREVE ECO-PUL with food-safe testing), W-455 (FoodSAFE standard), and W-287 (FoodSAFE REPREVE). The W-455 and W-287 variants are part of the formal ProSoft FoodSAFE® product line with explicit FDA 21 CFR documentation. W-288 carries the same food-safe testing but is branded as a REPREVE ECO-PUL product with food-safe as an additional feature. All three are suitable for direct food contact applications.

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

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

Choosing Your ProSoft® Lightweight ECO-PUL™

ProSoft® Lightweight ECO-PUL™ variant selection comes down to three questions: food-contact requirements, sustainability preference, and recycled content.

Variant Decisions

Do you need food-contact certification?
Three variants carry food-safe certification for direct food contact: W-455 (FoodSAFE standard polyester), W-287 (FoodSAFE REPREVE recycled), and W-288 (REPREVE ECO-PUL with food-safe testing). All three are tested safe for direct food contact from freezer (-20°C) to 250°F across all food types. Choose any of these for reusable sandwich wraps, snack bags, bowl covers, and lunch bag linings. The standard variant (W-579) is not food-safe certified — choose it when food contact is not involved.

Do you need recycled content?
Three variants use REPREVE recycled polyester: W-288 (10 bottles per yard, ECO-PUL branded with food-safe), W-287 (8 bottles per yard, FoodSAFE branded), and both deliver identical waterproof and breathability performance to standard polyester. Choose REPREVE when sourcing policies, brand positioning, or customer values require verified recycled content.

Do you need formal FoodSAFE® branding?
W-455 and W-287 are part of Wazoodle's ProSoft FoodSAFE® product line with explicit FDA 21 CFR documentation cited on the product. W-288 carries the same food-safe testing but is branded as a REPREVE ECO-PUL product. For product makers who need to reference specific FDA compliance documentation on their own product packaging or marketing, the FoodSAFE-branded variants provide the clearest certification trail.

If none of these features apply, the standard variant (W-579) offers the widest width range (53"–60" vs. 58"–60" for the others) and performs identically on all waterproof and durability specifications.

Note that some users report the 10% crosswise stretch can feel excessive in applications requiring rigid dimensional stability. For structured bag construction or applications needing a firmer body, heavier PUL weights provide more stability.

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

Working With ProSoft® Lightweight ECO-PUL™

ProSoft® Lightweight ECO-PUL™ requires the same PUL construction techniques as heavier ProSoft fabrics, with extra attention to the thinner, more flexible material.

The 0.013" thickness makes this fabric noticeably softer and more pliable than standard PUL — users describe it as a softer alternative to waterproof canvas that works well in layered garment construction without compromising drape.

Machine Setup & Sewing Techniques

Presser foot: A Teflon/glide foot or walking foot is essential — the thin PUL surface sticks to standard presser feet. Alternatives: sew through wax paper, or dab a small amount of sewing machine oil on the foot.
Needles: Use ballpoint/jersey needles (sizes 75/11 or 80/12) 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.
Speed: Reduce sewing speed — the lightweight material feeds faster than heavier PUL and benefits from slower, controlled stitching. Low to medium speed also prevents heat buildup at the needle.
Cutting: Rotary cutter or sharp scissors. Edges don't ravel (knit construction), eliminating edge finishing. Cut across grain for stretch in binding applications, with grain to limit stretch.

Seam Sealing Heat-activated seam sealing tape must be applied over all sewn seams. Every needle hole through the TPU film compromises the waterproof barrier, and the tape melts into those holes to restore it. Apply with warm iron on the fabric side only.

Critical: Every needle hole permanently compromises waterproofing. Use clips instead of pins, 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. Manufacturing odor from thermal bonding dissipates after a wash-dry cycle or 24–72 hours of airing.

Pairing ProSoft® Lightweight ECO-PUL™ With Other Fabrics

ProSoft® Lightweight ECO-PUL™ serves as the waterproof barrier layer in multi-layer constructions. The 100 GSM weight and 0.013" thickness make it particularly well-suited as a hidden liner where bulk must stay minimal — inside garments, wallets, lightweight bags, and slim pad constructions.

Absorbent Partners (Above PUL Barrier)

Zorb® Original: Enclosure-required absorbent fabric for rapid liquid capture. Position between a skin-contact surface and the Lightweight PUL 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 top layer. Pairs with Lightweight PUL underneath. For details, see Zorb® 3D Stay Dry Dimple: The Complete Guide to Wazoodle's Premium Stay-Dry Absorbent Fabric.

Surface & Shell Partners

ProCool® Performance Interlock: Moisture-wicking surface layer for skin-contact positions. 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 marketed on organic credentials. For details, see ProECO® Organic Cotton Fleece: The Complete Guide to Wazoodle's Premium Organic Cotton Fabric.

Proven Layer Stacks

Reusable menstrual pad: Skin-contact topper (ProCool® Interlock or cotton) → absorbent core (Zorb® Original) → ProSoft Lightweight ECO-PUL (W-579 or REPREVE W-288) as slim waterproof backing.
Incontinence liner: Surface fabric → absorbent core → ProSoft Lightweight ECO-PUL as thin-profile waterproof barrier that remains flexible against the body.
Reusable food storage bag: ProSoft FoodSAFE Lightweight PUL (W-455, W-287, or REPREVE W-288) as the complete bag shell — food-safe certified surfaces eliminate the need for a separate food-contact liner. The 0.013" profile creates bags that fold flat for compact storage.
Garment gusset or liner: Outer garment fabric → ProSoft Lightweight ECO-PUL (W-579) as a hidden waterproof barrier — the 0.013" profile adds waterproofing without changing garment drape. Customers use this for underarm sweat-protection gussets in undergarments.
Waterproof pocket in clothing: ProSoft Lightweight ECO-PUL (W-579 or W-287) incorporated as pocket material in dresses and skirts — lightweight and flexible enough for garment construction while providing waterproof functionality.

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

ProSoft® Lightweight ECO-PUL™ Applications

ProSoft® Lightweight ECO-PUL™ is customer-validated across personal care, humanitarian, food storage, garment, and accessory applications. The minimal-bulk construction opens uses where standard-weight PUL feels too thick or heavy.

Cloth diapers and baby care include diaper covers, wet bags, diaper bags, and changing pads — applications where the thin profile reduces bulk against a baby's body.

Menstrual and incontinence products represent the largest customer category. Makers construct reusable menstrual pads, period underwear, and incontinence undergarments. Church sewing groups and nonprofit organizations produce reusable menstrual pad systems in bulk for girls and women in Malawi, Africa, and other communities where disposable products are unavailable.

Food storage leverages the food-safe certified variants for direct food contact applications. FoodSAFE variants (W-455, W-287) and the REPREVE variant (W-288) are all certified for both-sides food contact from frozen to 250°F. Reusable sandwich wraps, snack bags, bowl covers, and lunch bag linings replace single-use plastic with a washable, certified-safe alternative. The 0.013" thickness creates bags that fold flat and store compactly — an advantage over heavier PUL for food storage where minimal bulk is valued.

Garments and accessories represent distinctive lightweight PUL applications: underarm sweat-protection gussets in undergarments, credit card slot reinforcement in wallets and purses (thin enough to prevent bulk), makeup bag interior linings (soft waterproofing without canvas rigidity), waterproof pockets in dresses and skirts, spa pillow covers, and apron backing. The fabric also allows partial light transmission, enabling uses like shower-window covers where both waterproofing and some transparency are desired.

Pet and outdoor applications include dog raincoats and waterproof cage liners.

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

ProSoft® Lightweight ECO-PUL™ Certifications & Safety

ProSoft® Lightweight ECO-PUL™ holds certifications for children's product safety, chemical-free manufacturing, and international regulatory compliance across all variants. FoodSAFE variants additionally carry FDA food-contact certification.

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 for listed chemicals.
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.
Phthalate-Free: No restricted phthalates.
pH Neutral: Confirmed no acidic or alkaline residues per independent lab testing.
Hypoallergenic: Latex-free, vegan construction.

Food-Contact Certification (W-455, W-287, W-288)

FDA 21 CFR 177.1680 (W-455, W-287): Polyurethane resins certified for repeated-use food contact.
FDA 21 CFR 175.300 (W-455, W-287): Resinous and polymeric coatings certified for food-contact surfaces.
Food-Safe Certified (W-288): Both sides tested for direct food contact from -20°C to 250°F.
Both-Side Certification: All three food-safe variants are certified for direct food contact on both fabric and film sides across all food types (baked goods, dairy, fats, acidic foods, beverages) from frozen storage to 250°F.

Fabric vs. Finished Product: These certifications apply to the ProSoft Lightweight 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.

For what these certifications mean, 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® Lightweight ECO-PUL™

ProSoft® Lightweight ECO-PUL™ maintains its Waterproof 300X Technology (300+ wash cycle durability) when care protocols protect the polyurethane film. The thinner film is somewhat more sensitive to heat than heavier PUL — warm water extends lifespan better than hot.

Washing

Hot water is acceptable (up to 165°F) but warm water extends film life. Use zero-residue liquid detergent with an extra rinse cycle. Non-chlorine oxygen bleach is acceptable sparingly.

Drying

Medium heat only — never exceed 130°F (50°C). High heat causes film shrinkage that can appear as delamination. Line drying is always safe.

Avoid completely

Fabric softeners (permanently destroy waterproofing and breathability), chlorine bleach (damages film), vinegar and baking soda (cause delamination), dryer sheets (coat the film).

For complete ProSoft PUL care protocols, see ProSoft PUL Care Guide.

ProSoft® Lightweight ECO-PUL™ Technical Specifications

ProSoft® Lightweight ECO-PUL™ variants share identical performance specifications across all four options. The differences are base fiber (standard vs. recycled polyester), width range (W-579 offers 53"–60" vs. 58"–60" for the others), recycled content (W-288 at 10 bottles/yard, W-287 at 8 bottles/yard), and food-contact certification (W-455, W-287, and W-288).

All four variants: 100 GSM / 2.9 oz/sq yd weight, 0.013" ± 10% thickness, 60% polyester / 40% polyurethane composition, 225 psi hydrostatic pressure (~158,000 mm waterproof rating), 850 g/m²/24h MVTR breathability, 152 psi burst strength, 10% crosswise stretch, minimal lengthwise stretch and shrinkage, UPF 25–35 (lighter colors 25, darker colors 35), pH 7.4 neutral, coefficient of friction 0.26–1.9, color fastness 4.5.

Variant	SKU	Width	Base Fiber	Recycled Content	Food-Safe
Standard Lightweight	W-579	53"–60"	Standard polyester	—	—
REPREVE Lightweight	W-288	58"–60"	Recycled polyester	10 bottles/yard	No
FoodSAFE Lightweight	W-455	58"–60"	Standard polyester	—	FDA 21 CFR 177.1680, 175.300
FoodSAFE REPREVE Lightweight	W-287	58"–60"	Recycled polyester	8 bottles/yard	FDA 21 CFR 177.1680, 175.300

All measurements ±10% manufacturing tolerance. ASTM test methods: MVTR per ASTM E 96, hydrostatic pressure per ASTM D 751, burst strength per ASTM D3786.