Who This Checklist is For
If you're ordering Outlast fabric for the first time—or even if you've done it a few times—this checklist is for you. It's not for the textile engineer who's been specifying PCM materials for a decade. It's for the buyer, the product developer, or the production manager who needs to get the order right the first time. Six steps. That's it.
Step 1: Verify Your PCM Technology Type
Here's the thing: not all Outlast fabric is the same. The phase change material (PCM) can be integrated in two primary ways:
- Outlast Aerogel: A newer, lighter integration for high-performance apparel
- Outlast Microencapsulated PCM (mPCM): The traditional, proven method embedded in the fiber or coated on the surface
I once ordered "Outlast fabric" for a line of motorcycle jackets. The spec sheet just said "Outlast temperature-regulating textile." I assumed it was the mPCM version we'd used before. Turns out, the supplier shipped the Aerogel variant—which, while excellent for base layers, didn't have the durability for abrasion-resistant outerwear. That error cost $890 in redo plus a 1-week delay. Now I check the specific PCM integration type before anything else.
If I remember correctly, Outlast's licensing typically specifies the integration method. Ask your supplier for the exact Outlast certification code for the fabric roll. "Outlast" isn't enough. You need the specific technology identifier.
Step 2: Confirm the Fabric Construction
Outlast technology is applied to a base fabric. You need to specify the construction separately. Is it a knit? A woven? A non-woven? What's the GSM (grams per square meter)?
The mistake I made in late 2022? I specified "Outlast fabric, 200 GSM" thinking the GSM referred to the total weight including the PCM coating. It didn't. I ended up with a fabric that was 180 GSM base + 20 GSM PCM coating = 200 GSM total. But the spec I actually needed for the jacket lining was 180 GSM base with a specific PCM add-on weight for the thermal regulation effect we wanted.
Get the base fabric specs in writing. GSM. Yarn count. Weave/knit structure. Most importantly, ask: "Is the PCM applied as a coating or embedded in the fiber?" This affects wash durability, hand feel, and cost.
Step 3: Check the Temperature Regulation Spec (The Critical One)
The reason you're ordering Outlast is the temperature regulation. But what temperature range? Outlast PCM is designed to absorb, store, and release heat within a specific melting/freezing temperature range. Common ranges include:
- 18°C (64°F) — for bedding and sleepwear
- 28°C (82°F) — for activewear and outdoor gear
- 32°C (90°F) — for industrial/workwear
Here's the thing: I assumed the standard Outlast PCM was a one-size-fits-all solution. It's not. We ordered fabric for a line of motorcycle jackets designed for summer riding (ambient temps 25-35°C). The 18°C PCM was wrong. It was constantly trying to cool the rider. The 28°C version was the correct spec. The surprise wasn't that the fabric worked—it was that it worked against the intended use case. Three things to specify: melt point temperature, enthalpy (total heat storage capacity in J/g), and the intended use environment. In that order.
Step 4: Validate the Color and Dye Process
If you're ordering colored Outlast fabric—say, a specific chartreuse satin for a high-visibility outdoor jacket—you need to confirm the dye process. PCM-treated fabrics, especially those with coatings, can behave differently in dye baths.
I'll be honest: I didn't know this until a $2,100 order came back with uneven dye take-up near the material's edges. The PCM coating on the surface was absorbing the dye differently than the base polyester. The result? A mottled, uneven color that looked fine in the roll but terrible on a finished jacket. (Should mention: we'd also ordered velvet chaise fabric from the same supplier. That order had no issues because the velvet pile masked any dye variation.)
Ask for a dyed sample on the exact Outlast fabric construction. Not on the base fabric without PCM. On the actual treated fabric. And do it under the lighting conditions your end product will be viewed in.
Step 5: Confirm the Durability Requirements
Outlast PCM's longevity depends on the integration method and the end use. For apparel that will be washed repeatedly, you need PCM embedded in the fiber, not applied as a coating. For industrial applications like geotextiles or automotive interiors, the PCM needs to withstand mechanical abrasion and temperature cycling.
On a 3,200-piece order for outdoor gear, every single item had the issue: after ten washes, the thermal regulation effect dropped by 40%. The PCM was coated, not embedded. That error cost a lot more than the $890 redo from Step 1. It cost us a client relationship. Lesson learned: ask for the ASTM D7027 wash durability test results on the specific Outlast fabric construction. If the supplier doesn't have them, that's a red flag.
Step 6: Get the Certification Paperwork in Order
Outlast is a licensed technology. The fabric you're ordering should come with a certification of authenticity from Outlast Technologies. No certification? It's either counterfeit or a generic PCM product marketed as "Outlast-compatible." They are not the same.
The $3,200 mistake I referenced in the title? That was in Q1 2022. I ordered what I thought was certified Outlast fabric for a contract with a major outdoor brand. The supplier sent fabric that looked right, felt right, and even performed okay in informal tests. But when the brand's quality team asked for the Outlast certification, it didn't exist. The fabric was a generic PCM polyester with no licensing. The entire order—$3,200 worth—was rejected. Plus a damaged relationship with the brand.
Before you approve the final order, request: the Outlast license agreement, the batch-specific test report from Outlast, and the supplier's authorized manufacturer certificate. This was true 10 years ago when counterfeiting was easier. Today, Outlast has a digital verification system—use it.
Common Mistakes I Still See (and Made)
- Assuming all Outlast fabric has the same wash durability. It doesn't. Embedded PCM lasts longer than coated PCM. Know the difference.
- Skipping the temperature range verification. I did this. The cost was an entire production batch that had to be re-sleeved in a different lining.
- Forgetting to check the minimum order quantity (MOQ) for certified fabric. Outlast's licensed mills often have higher MOQs for certified product. I once designed a jacket around a fabric that had a 500-yard MOQ. I needed 150. The project died.
Bottom line: Outlast fabric is a technical product. Treat it like one. Download this checklist, adapt it to your workflow, and run every order through it. It won't prevent every mistake, but it'll catch the expensive ones. I know because I've made most of them.