What Is Flannel and Why Is It So Popular?

Flannel has been a closet staple for generations, loved for its warmth, softness, and laid-back style. But what, exactly, is flannel? And why is it so popular? 

This cozy fabric has a surprisingly rich history, from its practical beginnings in the Welsh countryside to its iconic role in workwear and fashion movements around the world. But what is a flannel shirt, what are flannels made of, and how did it become such a timeless wardrobe staple? In this guide, we’ll define flannel, explain what it’s made of, explore why it’s so loved, and share simple tips on how to wear and care for it.

What is Flannel Made Of?

Flannel is made from soft, woven fibers like cotton, wool, or a blend of both. These materials are brushed to lift fine strands from the surface, giving flannel fabric its signature warmth and fuzzy texture.

Most woven flannel is made from:

• Cotton: Lightweight, breathable, and soft against the skin for year-round comfort

• Wool: Naturally insulating and durable, offering extra warmth and structure in colder weather

• Blends: Combine cotton, wool, or synthetic fibers to balance softness, strength, and easy care

Flannel’s fuzzy texture comes from the brushing process, where large rollers gently raise fine fibers from the yarn. This can be done on one or both sides of the fabric, creating that signature fluffy feel while keeping a smooth finish. The loose weave underneath adds flexibility and helps trap heat without feeling heavy.

Because it’s warm, absorbent, and wrinkle-resistant, flannel is a favorite not only for shirts and jackets but also for bedding and loungewear. Its comfort and easy care make it suitable for everyday wear, yet durable enough to last season after season.

The Origin of Flannel

Flannel’s history is pretty cool — no chilly pun intended! Hailing from Wales, where the weather can be more than a little cold and damp, flannel was crafted from the materials close at hand. Thanks to the abundance of Welsh sheep, the locals had plenty of carded wool to spin into garments designed to battle the cold.

Born from the need to stay dry and warm in the rugged conditions of the Welsh countryside, this humble fabric was eventually adopted throughout Europe, delivering comfort and functionality along the way.

Flannel in U.S. Fashion

So, when did flannel become popular in the U.S.? By the 19th century, America was knee-deep in the Industrial Revolution — the perfect time for flannel to thrive thanks to its cozy feel, affordability, and durability.

Imagine a fabric so versatile it could keep you cozy as a blanket, work hard as a shirt, and even show up as undergarments — while staying durable and easy to clean.

From those functional roots, flannel also found its way into everyday culture. Most notably, it was the standard uniform for all things grunge during the 1990s, where it was paired with ripped jeans and combat boots by iconic bands like Nirvana, Pearl Jam, Soundgarden, and Alice in Chains, not to mention their devoted fan bases. What started as Seattle’s answer to cold and rainy days became a worldwide symbol of distorted guitars and packed mosh pits — a true cultural icon if there ever was one.

Why Are Flannels So Popular?

Flannels are popular because they combine warmth, durability, and easygoing style in one fabric. They’re soft enough for lounging, tough enough for adventure, and timeless enough to stay in style year after year. Let’s take a closer look at what makes flannels a go-to closet staple for people around the world.

Durability

One big reason why flannels are a closet must-have? Their durability. This robust, woven fabric can withstand significant wear and tear (remember its origins: the winds and cold of Wales). This makes it a great choice for workwear, casual wear, and bundling up for a long day out in the cold without the fear of tears, holes, or stretching.

And for those who have physically demanding jobs, all the better. Flannel shirt material is even more valuable for them, providing all-day comfort with a durable build that’s easy to wash and dry. No high-maintenance care needed! 

Warmth

Flannel is especially known for its warmth, but what is flannel material’s secret? Remember that weaving process we mentioned earlier? The napping of the fabric creates tiny pockets that trap air and keep you warm. Don’t worry – this warmth doesn’t come at the expense of comfort, as flannel isn’t just insulating. It’s also incredibly breathable, so you don’t feel overheated when wearing it. In other words, you get all the toasty benefits without feeling weighed down. 

Of course, we can’t talk about warmth without discussing layering flannels. Flannels' natural insulation properties make them excellent candidates for creating cozy, cold-weather ensembles. By wearing multiple flannel shirts or incorporating them as mid-layers, you can trap heat effectively, ensuring that you stay snug and toasty even in the chilliest of conditions. 

Style

There’s something timeless about flannel shirts. They seem to fit in anywhere and never go out of style. Their classic plaid or tartan patterns have become a staple in men's fashion, effortlessly crossing boundaries from casual to upscale, from sports arenas to rock concerts.

Simply put, flannels’ versatility knows no bounds. From cozy pajamas to rugged, casual looks, flannel works across countless styles without even trying. Flannels can also be mixed and matched with different patterns and colors to create unique and stylish layered outfits.  

Versatility

Looking for something polished? Pair a flannel shirt with khakis. Prefer to keep it casual? Throw it on with some baggy jeans. 

They're the perfect piece to adapt to changing weather or switch up your style on the fly. Layer them over a t-shirt for a relaxed look, under a sweater for extra warmth, or even with a pair of slacks for a dash of rugged sophistication. These quintessential garments effortlessly transition from cozy loungewear to stylish fashion statements in a snap.

Are Plaid and Flannel the Same Thing?

No, plaid is a pattern, and flannel is a fabric.

Plaid refers to a visual design made of intersecting lines and colors, while flannel describes the soft, brushed material itself. You can find plaid patterns on many fabrics, and flannel can come in solids, stripes, or other prints.

How to Wear Flannel

Flannel’s versatility doesn’t stop at comfort. It’s also one of the easiest fabrics to style.

Flannel is one of those fabrics that works with almost anything — rugged or refined, layered or simple. Whether you’re heading out for the weekend or layering up for cooler weather, there’s a flannel look for every style.

Flannel shirt: Wear open over a tee with denim for weekends, or buttoned with chinos for a cleaner look. Roll the sleeves and tuck or untuck depending on your vibe.

Flannel jacket/overshirt: Layer over a henley or hoodie and finish with dark denim or work pants. Boots or classic sneakers both work.

Flannel hoodie: Pair with joggers or relaxed jeans and sneakers for effortless streetwear. Add a long-sleeve tee underneath when temps drop.

Patterns and color: Mix plaids with solid basics and keep one pattern dominant to avoid clashing. Earth tones are timeless; bold checks make a statement.

No matter how you style it, flannel brings comfort, character, and that easygoing confidence UNIONBAY is known for.

How to Care for Flannel

Flannel stays soft and durable with gentle washing and drying.

To keep your flannel shirts looking and feeling their best, wash them in cold or warm water on a gentle cycle. Hot water can cause shrinkage and weaken the fibers. Use a mild detergent and skip the fabric softener, as it can flatten the fabric’s brushed texture.

When washing flannel, turn garments inside out to reduce friction and fading. You can tumble dry on low heat, but air drying is even better. Hanging your flannel to dry helps maintain its shape, color, and cozy feel.

Ironing is rarely needed. If you prefer a crisp look, use a low-heat setting and iron inside out to protect the fibers. Always check the care label for details to keep your flannel soft, warm, and ready for years of wear.

Quick care tips

• Wash: Cold or warm water, gentle cycle, mild detergent.

• Dry: Low heat or hang to air dry.

• Iron: Only if needed, on a low-heat setting, inside out.

Stay Stylish with Flannels From UNIONBAY

From its Welsh beginnings to modern streetwear and workwear, flannel has truly stood the test of time.

Whether you love it for its cozy texture, versatile styling, or classic plaid patterns, flannel remains one of the most enduring fabrics in fashion. Its warmth, comfort, and effortless style make it a reliable favorite season after season.

Explore the UNIONBAY flannel collection to find your new favorite shirt, jacket, or hoodie. With a range of colors and classic patterns, there's a perfect flannel for every style. Have a question? Contact us anytime. We’re happy to help.

Stay cozy, stay classic — that’s the UNIONBAY way.