I made some pjs in flannel but I thought flannel was too thick...
But I don't want to use quilting cotton.
What is a good cotton fabric for pj?
Does cotton sateen work?
What do they use in RTW pj that feels like flannel but a lot thinner?
The winter ones I love the most are just worn out. They were a wearable muslin from some of that thin cheap brushed knit that looks like flannel but is not I had bought a large piece of off a clearance table long ago. They are so soft. I made two pairs from a big piece of nice flannel and stupidly donated them as they were too hot/thick to sleep in. I don't get all that much sewing time anymore and realized after giving them away they would be great for lounging in winter or pulling on to morning walk the dogs in our isolated area since they were earth toned solid and thick. I actually sometimes use soft cotton sheets for pjs/gowns as they take so much fabric and I now test patterns before committing to quality pricey fabrics and often find the sheet versions work fine for real wear. Just make sure they are soft,good cotton not stiff with a coated finish for permanent press. I think you have to make some different fabrics before you find what works for your climate and preference. That brushed knit was a whole different fabric than the regular flannel for me.
Cotton lawn or cotton batiste are great for light weight summer pajamas. In fact, batiste is used for a lot of heirloom sewing, which techniques are incorporated in a lot of lingerie. I have some nice Vera Wang pjs that are made from rayon knit and they are super comfortable. For something warmer, a nice cotton interlock would work. I have used quilting cotton for pj bottoms - the lighter weight ones seem to be more comfortable. Another option is linen. Fabric Store has a great selection of different weight linens for reasonable prices. Another warmer option is flannel backed Satin. I have even seen this at JoAnns. Good luck with your pj sewing!
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Fabrics and more... >> What is a good fabric for PJ?