Every sheet starts as a cotton plant. After harvesting, the raw cotton is ginned, a process that separates the fibres from the seeds. The length of these fibres (called the staple) determines the quality of the yarn they'll become.
Long-staple cotton, typically 34–38 mm, produces smoother, stronger yarn with fewer joins. This is what gives high-quality sheets their softness and durability. Short-staple cotton, while cheaper, creates rougher yarn that pills more easily.
The cleaned fibres are combed and drawn into thin strands, then spun into yarn. The tightness of the spin affects the feel: a looser spin creates a softer yarn (ideal for sateen), while a tighter spin produces a crisper hand (used in percale).
The yarn is then woven on a loom. The weave pattern, percale's balanced one-over-one-under versus sateen's four-over-one-under, determines the fabric's texture, sheen, and drape.
After weaving, the fabric goes through finishing: washing, softening, and sometimes mercerising (a treatment that strengthens the cotton and adds lustre). It's then cut, sewn, and quality-checked before it reaches you.
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