Provided herein are flame resistant fabrics having a thermoplastic fiber content of as much as 65% (where no more than 5% of the fibers are non-thermoplastic synthetic fibers). The flame resistant properties are imparted by treating the fabric with one or more flame retardant chemicals and then by curing the treated fabric at high temperatures. Optionally, softeners, stain release agents, soil repellent agents, permanent press resins, and the like may be added to the bath of flame retardant chemicals. Alternately, the treated fabric may be subjected to mechanical treatment to increase softness. The fabrics produced by the present process exhibit improved performance and tear strength, as compared to conventionally treated fabrics.