The aim of this work is to develop Thick-Thin polyester yarn(T-T yarn) with finer than 1 denier mono filament. The manufacture of T-T yarns were carried out in a draw-winder using 85d/72f PET filament with various spinning speed of 2700, 2900, and 3100 m/min, respectively. The structure and physical properties of T-T yarns with spinning speed and over feed ratio were examined by draw-winder processing the sample in $100^{circ}C$ water for 20 min and drying in 120, 140, 160, and $180^{circ}C$ of dry air for 20 min. The crystallinity, the birefringence and the initial elasticity modulus of T-T yarns increased with increased spinning speed of filament and the heat treatment temperature but at the temperatures higher than $140^{circ}C$ the increased rates show a tendency to decrease. Moreover, the initial modulus and the tenacity of T-T yarns increased with decreasing the over feed ratio of filament and the those of T-T yarns decreases with increasing the heat treatment temperature. The shrinkage of T-T yarns decreased with decreasing spinning speed and increased over feed ratio of filaments. Consequently, the results indicate that the best T-T yarn under 1 denier was optimized from PET filament with spinning speed of 2700 m/min and over feed ratio of 0.67