Over the past few years, research has been done at the University of Tennessee, Knoxville to produce and evaluate nonwoven products containing cotton with different binder fibers. Using a thermoplastic binder fiber is the best route to produce quality nonwovens using the most convenient and simple method of bonding, i.e., thermal calendering. The challenge is to find the right binder fiber that is biodegradable and works better with cotton. Several combinations of cotton and biodegradable thermoplastic fibers, traditionally available and new varieties, are being investigated. Whereas some of the newer polymers/fibers show a great deal of promise, having the right type fiber, and in right combination is important in achieving the desired properties. The production of nonwovens by the thermal bonding process from such compositions, and the structure and properties of the resulting products will be discussed.