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I sewed, used on my babes, and sold polar fleece diaper covers for six years. I have a child who cannot wear FOE next to her skin because she will break out in a red welt. She had no problem with polar fleece.
Anu, no way is polar fleece the same as the hot nasty poly fleece that blanket sleepers are made out of.
Polarfleece is actually a high-tech material that's made for sports and outdoor activities like hiking & camping. It's made to wick moisture from the body, cool the person off when needed & keep them warm when needed, and it definitely breathes.
It is similar to wool. Do I prefer wool and cotton? Yes, sometimes. But sometimes, be it for diaper covers or pants for hiking or a jacket, I really prefer polar fleece. It's light, comfy and soft, and easy to clean.
It is made of petroleum products. So are soda bottles. It is made of recycled soda bottles sometimes, but still petroleum then. So is the computer you are typing on, so are many many things throughout our lives. Everything plastic. To me, polar fleece is one of these types of products that I really like and enjoy.
I never used fleece liners next to my baby's genitals, personally. I only made them occasionally when people really wanted me to. I don't like the idea, because it is polyester and because it seems extra warm and not very comfy to me. Just a personal preference thing, I think. But as a diaper cover, with the cuffs next to the skin? That seems fine to me as long as the child doesn't have an allergic reaction - which can happen with any fabric.
I have researched the heck out of it, since it was my business. I have never found any reputable links or reports linking polar fleece to any sorts of health issues whatsoever.
ETA: I have used them in Alaska and in Florida, in -50 F and 100 F, and all temps in between. They have always kept my kids comfy, never too hot. Never nearly as hot as PUL or anything like that! I find them comparable to wool in this regard; perhaps just a touch less cool in the heat, but to me that was fine for the easy care they allow...wool is a PITA to me sometimes, esp when outside a lot and dirt and such would get on the soakers.
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