These days most base layers are either made of synthetic materials – typically polyester or polypropylene – or merino wool, though hybrid designs featuring both are becoming more and more popular. While the end goal remains the same, both materials achieve it in slightly different ways, and with different pros and cons.
Synthetic sports underwear
Many mountain clothing manufacturers now have their own proprietary synthetic fabrics, the most well known of which are Helly Hansen’s Lifa® and Patagonia’s Capilene®, though most are fairly similar in terms of materials. They are usually cheaper than their merino counterparts, and wick sweat much better. The downside is that they often become smelly quite quickly; you can’t get away with wearing synthetic base layers for multiple days in a row like you can with merino.
How does synthetic thermal underwear work?
Synthetic base layers manage moisture by ‘wicking’ it away from your skin, in a similar way to how a lit candle wick draws wax along its length. This process, where liquid is drawn along a fibrous path, is properly known as capillary action. During high activity sport moisture and heat build up inside the base layer, creating a temperature and humidity gradient between the inside and outside of the garment. This is the driver of the wicking process – the highly humid air inside the garment naturally wants to move towards equilibrium, which means it wants to move to the lower humidity environment outside. As sweat comes into contact with the synthetic material, it is drawn along the fibres – without being absorbed – and out through tiny holes in the weave to the outside of the garment where it can evaporate away without chilling the body.
Due to their ability to better manage moisture, synthetic base layers remain the top choice for high output activities like ski touring, though as they require more frequent washing than merino they are more appropriate for day trips and single uses. They generally feel nice and smooth against the skin and dry much quicker than wool, so feel less muggy and weighty after heavy perspiration.
Pros and cons of Merino
Merino has been one of the buzzwords in the outdoor industry for the last few years, and for good reason. This almost too-good-to-be-true natural fibre is ideal for base layers: it manages moisture well, it remains warm when wet, and it can take literally WEEKS’ worth of sweat before it starts to smell and requires washing. The downsides are that it is typically more expensive than synthetic garments, doesn’t deal with moisture as well, takes longer to dry, and is less durable. Cheaper, lower-quality merino can also be itchy next to the skin – you get what you pay for, here.
Technically, merino doesn’t actually wick sweat, though the end result is the same. Rather than drawing moisture along fibres and out through tiny gaps in the weave, merino fibres actually absorb it. The inner core, or cortex, of a merino fibre is capable of absorbing over 30% of its own weight in moisture, which through the same humidity gradient outlined above is then drawn to the outside of the garment where it can evaporate away. We are typically taught that materials that absorb so much moisture – like cotton – are bad for base layers, but merino has a trick up its sleeve. The outsides of wool fibres are coated with a waxy substance called lanolin, which is water resistant. As this hydrophobic layer is the part that touches your skin, the feeling of dampness is reduced even when the garment is soaked. The same layer also helps wool garments shrug off light rain.
Merino wool has the additional benefit of retaining its insulating properties even when wet – and in fact even generates heat through the process of water absorption. Moisture is absorbed into the wool fibres in a reversible chemical reaction through the interaction of hydrogen bonds. The reaction generates heat when water is absorbed, and takes it up when the moisture is shed; this ‘magic’ is known as ‘heat of sorption.’ It allows wool garments to act as a ‘buffer’ to the wearer in changing environments: in cold climates relative humidity is typically higher outdoors than indoors, so a merino garment ‘conditioned’ to the drier environment indoors will immediately begin producing heat as it absorbs moisture when you go outside. This process typically occurs within two to five minutes, slowing down as the moisture content of the wool reaches equilibrium with the higher relative humidity of the new environment.
The downside of merino’s huge water absorption capability is that it takes longer to dry than synthetic materials, and so can feel heavy and slightly uncomfortable when saturated. It is best suited to lower intensity activities in cold weather, and due to its odour-resistance, longer trips where you don’t have the luxury of changing layers every day. Your friends will thank you for wearing merino layers on long ski boat trips or while tent-bound in a storm! Merino is also less durable than synthetics and requires more care when washing and drying, plus it’s usually more expensive.
Hybrid underwear made of synthetic and merino wool
Many brands are now using a combination of synthetic and merino fibres to create hybrid garments. These pieces combine the best attributes of both materials to produce excellent base layers that are great for all around use. They typically resist odour and insulate much better than synthetic garments (though not quite as well as pure merino), and manage moisture better and are more durable than pure merino.