In addition to the intrinsic physical and mechanical properties of fabrics, surface modifications and sewing process variables significantly influence the quality of the final product. Among the relevant evaluation criteria, needle penetration force and fabric bending length could be considered as the two key parameters for assessing these effects. The present study investigates and models these two parameters in plasma-treated cotton and worsted woven fabrics. For this purpose, samples of cotton and worsted woven fabrics were subjected to plasma treatment, and the needle penetration force and bending length were experimentally measured. To determine the most influential plasma variables, a D-optimal factorial design was employed. The plasma process parameters included treatment time (3, 6, and 10 min), power (50, 100, and 150 W), and gas flow rate (50, 100, and 150 cm³/min). The statistical analysis of the experimental data revealed that all plasma parameters had a statistically significant effect on both needle penetration force and bending length of the fabrics. Subsequently, the third-order regression models were developed to predict the needle penetration force and bending length. The coefficient of determination (R²) for the most accurate predictive models of needle penetration force in cotton and worsted fabrics was 0.86 and 0.93, respectively. For bending length, the R² values of the best-performing models were 0.79 for cotton and 0.42 for worsted fabrics. These findings indicate that the developed regression models can predict the needle penetration force to a significant extent based on plasma process parameters. However, the model performance in predicting the bending length, especially in worsted fabrics, is more limited and is likely to be affected by other factors.