Corduroy found a stronghold in the U.S., particularly in the late 19th and early 20th centuries, as America expanded westward. During the Western era, roughly from the mid-1800s to the early 1900s, corduroy was highly prized for its toughness and warmth, making it a practical choice for men living and working in harsh outdoor conditions.
Corduroy is woven using three sets of yarns: warp and weft yarns form the fabric's foundation, while pile yarns are woven into loops that create the characteristic ridges, or "wales." After weaving, the loops are precisely cut open to produce the soft, textured surface. The fabric is then brushed to raise the pile and enhance its velvety feel. The wale count, which measures the spacing of the ridges, determines the fabric's weight and texture.
