Vintage NOS bed linens vs. new

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Launderess, once again you are a font of information.  I had planned on darning with my sewing machine but the first method might work well, I have not come across that method before.

These are very heavy 100% cotton sateen sheets 600 or 800 thread count, never used, never washed. The pillow cases are over sized envelope type so I could steal a bit of fabric from them if need be. Looking for the strongest method to repair but would also like the repair not to be irritating to sleep on, what is your suggestion?
 
Have never truly liked machine darning. Know it is streets easier than when done by hand, but always feels hard, sort of like a scab.

Mending by sewing machine OTOH if done well and carefully produces a durable repair that will feel softer. Especially if area to be repaired is small enough to make mend nearly invisible.

If tear in your sheet is of small sort, I'd go with using your sewing machine to make repair. Long as surrounding material is strong enough to support repair things should be good to go for years.

Have several old French hemp and linen sheets that were mended at some point. This work was done by hand, is soft and nearly invisible. Don't have that kind of time nor wish to sacrifice one's eyesight.
 
I've tried darning expensive wool jumpers (sweaters) and made a TOTAL mess - it turned out like a spiders web. I'll have to learn how to do it properly sometime, as I've a few wooden items I really, really love and have ended up having to consign them to a closet of Stuff I can't bear to throw out!
 
Though not as common compared to past, you can still find bed sheets and pillow cases sold separately.

https://egyptianlinens.com/collections/fitted-sheet-only

Much of that rot began when fitted sheets largely replaced flat for use on bottom.

With flat sheets it is possible to rotate things between "top" and "bottom" so receive even wear. Bottom sheets receive most wear compared to top, so things evened out in end. This and it is easier to cut down flat sheets to smaller sizes or use for something else once it became too badly worn for main purpose.

With arrival of fitted sheets mills/manufactures would be often left with an inventory imbalance. Replacement of bottom sheet (fitted) because of wear, but top flat sheets galore because they wore out less quickly.

Back in day, and still today for all one knows it is fairly common only giving out one clean top sheet when linen supplies were tight. Hotels, hospitals and other places did this, and many still do. But it only works if all sheets are flat.

During my stint of hospital work if linen supply was tight making beds meant top sheet (which usually wasn't badly soiled) went on bottom, and only a fresh clean sheet and pillow cases replaces used.
 
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