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It is still a big challenge for textile industry in improving fire resistance and reducing melt dripping with minimal loss on the physical properties of polyethylene terephthalate (PET) fabrics. In this work, a highly-effective hyperbranched flame retardant (DT) was first synthesized by ester exchange without using any organic solvent. Then, the DT foam was prepared and blade coated on PET fabric to improve the fire performance. The prepared PET fabric with only 2.7% weight gain of DT was self-extinguished and did not produce any molten dripping during the vertical flammable test. The peak heat release rate and total heat release of the PET fabric sample with 19.4% DT were decreased by 42.0% and 57.1%, respectively compared with that of the control PET. Besides, the as-prepared PET fabric sample showed better physical properties such as breaking strength, vapor permeability, air permeability, antistatic property, and softness than the control PET fabric sample. The DT foam finishing process did not involve any organic solvent and consumed less water and energy compared with conventional fabric treatments. It is expected that this work provides a facile and eco-friendly strategy for fabricating flame retardant PET fabric with excellent comprehensive performances. [Display omitted] • A hyperbranched flame retardant (DT) was synthesized by a solvent-free approach. • Flame retardant PET fabrics were prepared by sustainable foam finishing. • The PET fabric with 2.7% DT was self-extinguished and free of molten drops. • The treated PET fabric showed excellent physical properties. [ABSTRACT FROM AUTHOR]