Fusion fiberfill was developed because of the high water and drying temperatures used by consumers with allergy concerns.

Initially, polyolefin and mixtures of polyolefin and polyester were used with less than desirable results.

The low melting point of polyolefin makes it a substandard choice for use in bedding items that are washed multiple times in a home setting, where the washing and drying temperatures vary greatly.

On the other hand, Fusion fiber is made from a polyester polymer with extremely high heat resistance. Each strand is highly polished to insure that the fibers move easily against each other to avoid lumping or clumping. Next, they are twisted or spiraled to give them a soft springy rebound when compressed in use. Finally, the fibers are joined in a conjugate fashion (symmetrical) resulting in a small cluster between one eighth to one quarter inch in diameter. The varying size of each cluster allows them to fit together and fill the voids between themselves providing a very comfortable sleeping surface.

Fusion fiber has become extremely desirable because it can resist very high washing and drying temperatures. This feature is extremely beneficial as it allows bedding items like pillows and comforters to dry faster than any other fiberfill.