Advantages and Disadvantages

Processed cotton materials are fairly lightweight and flexible. Cotton dyes easily, since the fibers are so absorbant. This natural property also makes cotton a good choice for linings which must be able to absorb sweat. Cotton is readily available and inexpensive.

However, cotton does suffer from some durability faults; it will wear and break under stress more easily than modern synthetics. Because of this, cotton should probably not be used for critical costume components.

Uses For Cotton

I use cotton mostly for testing sewing patterns. When I am working on tailoring a new pattern, I'll cut the pieces from cotton broadcloth (a simple woven fabric that has no stretch to it) first. I can then make the necessary seam adjustments on the cotton test suit in order to refine the pattern. The broadcloth is inexpensive enough that I can do two or three pattern tests without worrying about the expense.

As mentioned above, cotton is also useful as a layer underneath a suit. The cotton might be an undersuit or a lining sewn permanently into the fursuit.

If you need a little bit of padding and smoothing in a suit, you may also want to consider using "batted cotton" as a lining material. This is basically two layers of cotton fabric with fiberfill quilted between them; the batting, which is a mat of synthetic fibers, is sandwiched in place by patterns of stitching.

One cotton option which should be avoided is cotton thread. Most sewing is done with cotton thread because it's cheaper and easier to work with. However, the tensile strength of the thread is insufficient for a costume; I recommend you always use a synthetic polyester thread.