Spunbond vs Spunmelt Nonwoven Fabric — Key Differences Explained

If you are sourcing nonwoven fabric for a manufacturing application, you will quickly encounter two terms: spunbond and spunmelt. Both are polypropylene-based nonwoven fabrics produced through similar initial processes — but they differ significantly in structure, performance, and applications.

Understanding the difference between spunbond and spunmelt (also called SMS or spunmelt composite) is essential for specifying the right material for your product. This guide from Olefins explains both clearly.

What is Spunbond Nonwoven Fabric?

Spunbond is the base technology. Polymer granules are melted, extruded through spinnerets, drawn into fine filaments by high-speed air, deposited onto a conveyor to form a web, and thermally bonded by heated calendar rollers. The result is a single-layer fabric with consistent GSM, good tensile strength, and a uniform open structure.

Key characteristics: continuous filament construction (15–35 micron fibre diameter), open pore structure (breathable but not a barrier), good MD and CD tensile strength, soft hand feel at fine GSM, excellent uniformity and cost-effectiveness.

What is Spunmelt (SMS/SMMS) Nonwoven Fabric?

Spunmelt fabric adds a meltblown layer between spunbond layers. Meltblown uses extremely fine die holes and very high-velocity hot air to produce micro-fibres of 0.5–5 microns — 10× finer than spunbond. These micro-fibres create a dense barrier layer. SMS (Spunbond-Meltblown-Spunbond) and SMMS (double meltblown) are the most common constructions. All layers are produced and bonded in a single continuous pass.

Property	Spunbond	Spunmelt (SMS/SMMS)
Construction	Single layer of bonded filaments	2–4 layer composite with meltblown core
Fibre diameter	15–35 microns	Spunbond 15–35μm + meltblown 0.5–5μm
Barrier performance	Low — open structure	High — meltblown core blocks particles & liquid
Softness	Excellent	Very good
Strength	High	High (spunbond layers carry load)
Breathability	High	Moderate (meltblown reduces air flow)
Cost	Lower	15–40% higher than spunbond
Best use	Bags, hygiene, agri, packaging	Medical gowns, PPE, hygiene backsheet

When to Choose Spunbond

Shopping bags, agricultural covers, furniture backing — where barrier is not needed
Hygiene product topsheets — soft skin-contact layers requiring hydrophilic treatment
Geotextiles — where drainage and separation matter more than barrier
Packaging and wrapping — where breathability and cost are the priorities
Disposable light workwear — lab coats, caps, shoe covers not requiring fluid protection

When to Choose Spunmelt (SMS/SMMS)

Surgical gowns and drapes — fluid barrier is a clinical safety requirement
PPE coveralls for chemical or biological hazard environments
Baby diaper backsheets — hydrophobic barrier preventing reverse flow
Medical masks — SMS outer/inner with meltblown filtration layer
Any application requiring hydrostatic head pressure resistance

Olefins manufactures both spunbond and spunmelt (SMS/SMMS) nonwoven fabrics. Not sure which is right for your application? Send us your product details and we will recommend the correct specification.