This article reports on the analysis of the fiber overlap and fiber extent in ring, rotor, and air-jet spun polyester/viscose blended yarns. The fiber overlap and fiber extent was measured by employing the tracer fiber technique. Statistical analysis was carried out at the 95% significance level with the single tail test to trace out specific trends executed by the spun yarns with any change in their blend proportions. The fiber overlap index and spinning-in-coefficient is correlated with tensile characteristics (static and dynamic) of the spun yarns to explore the most influential structural parameter among them for different applications. This presents study indicates that the prediction of spun yarn performance in post spinning processes is more appropriately modeled based on fiber overlap index over spinning-incoefficient for ring and air-jet spun yarns, whereas spinning-in-coefficient is more appropriate for rotor spun yarns. For apparel use, spinning-in-coefficient is more appropriate over fiber overlap index for rotor and air-jet yarns to model the spun yarn strength as opposed to fiber overlap index for ring spun yarns.
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