Some properties of polyester fabrics are more desirable in comparison with other apparel fabrics. These properties include high strength, long aging time, high flexibility, low expenses etc. In order to obtain the optimum superficial and sensory properties like better handling, un sliding effect, appropriate optical properties, better drape, it would be necessary to evaluate some surface and mechanical properties. The main aim of this work was to optimize the polyester fabric characterization using the surface and mechanical properties. In order to do this, twenty of polyester fabrics were prepared. High twist filament yarns were used in weaving the samples. Four different wave patterns with five weft density were selected as independent variables. For each fabric type, three various test groups including surface protrusion, using image processing technique, bending properties and tensile properties in weft, warp and bias direction were performed. Statistical results showed that weft density and wave pattern have significant effect on surface protrusion, bending and tensile properties. The results of the tensile tests showed that, for all wave patterns, the resiliency and linearity of the fabrics in biased direction are much less in comparison to weft and warp directions. Keywords : polyester fabrics, surface protrusion, bending and tensile properties