When you’re buying a new T-shirt or planning a custom print, the same question always comes up: polyester or cotton?
Both fabrics are popular for good reasons. Cotton is natural, soft, and comfortable. Polyester is strong, long lasting, and great for active wear. They each have their own strengths, and knowing the difference helps you pick the right one for your needs.
In this article, you’ll learn:
- What makes cotton and polyester unique
- How each fabric performs for printing and daily wear
- Why blends are becoming more popular
- A quick comparison chart that makes the choice easier
By the end, you’ll know exactly which fabric fits your comfort, style, and purpose.
Table of Contents
- Polyester vs Cotton: Which Fabric Fits You Best
- What is Cotton Fabric
- Types of Cotton
- What is Polyester Fabric
- Types of Polyester
- Cotton vs Polyester: Key Differences You Should Know
- Cotton-Polyester Blends: The Best of Both Worlds
- Printing on Cotton, Polyester, and Blends
- Polyester vs Cotton vs Blends: Comparison Chart
- Conclusion: How to Choose the Right Fabric
- Frequently Asked Questions (FAQ)
What is Cotton Fabric?
Cotton is one of the most common fabrics in the world. It comes from the soft fibers that grow around the seeds of the cotton plant. Those fibers are spun into yarn and then woven or knitted into fabric.
People love cotton because it’s soft, breathable, and gentle on the skin. When you wear a cotton shirt, air flows through easily, helping you stay cool and dry. It’s also a great choice for printing since cotton fibers hold ink well and give designs a clean, bright look.
Cotton is also eco-friendly since it’s natural and biodegradable. But it does have a few downsides. It can shrink in the wash, wrinkle easily, and take longer to dry. Even so, cotton remains the favorite choice for comfort, softness, and everyday wear.
Types of Cotton
Not all cotton feels the same. The type of cotton used can change how soft it is, how long it lasts, and even how it looks when printed. Here are the main types you’ll find in clothing and blank apparel:
Upland Cotton
This is the most common type, used in most T-shirts and casual wear. It’s soft, affordable, and easy to care for.
Organic Cotton
Grown without harsh chemicals or pesticides, organic cotton is better for the environment and softer on sensitive skin. It’s a top pick for eco-friendly brands.
Pima Cotton
Pima cotton has longer fibers that make it smoother and stronger. It feels silky and resists fraying, which is why it’s used in premium T-shirts and luxury apparel.
Egyptian Cotton
Egyptian cotton is known for its fine, long fibers that create a soft, silky fabric. It’s often used in high-end clothing and bedding.
Airlume and Ringspun Cotton
Airlume cotton goes through an extra cleaning process that removes impurities and short fibers, making it smoother and more durable.
Ringspun cotton is spun tighter, creating a stronger, softer yarn. Together, they create a premium feel that’s perfect for high-quality printed shirts.
Pro tip:
If you’re printing shirts, carded open-end cotton is budget-friendly but a bit rougher. Combed and ringspun cotton is softer, smoother, and ideal for premium prints.
Cotton T-Shirt Examples
If you’re shopping for blank cotton shirts, you’ll notice a few popular options that fit different budgets and needs:
- Budget: Gildan G640 Adult Softstyle (4.5 oz) — a solid everyday cotton tee that’s soft and affordable. Great for bulk orders or giveaways.
- Standard: Next Level 3600 Unisex Cotton T-Shirt — a smoother, mid-weight cotton shirt that feels nice and holds prints well.
- Premium: econscious EC1007U Organic USA-Made T-Shirt (5.5 oz) — made with organic cotton for a heavier, eco-friendly feel and a cleaner print surface.
Each one offers a different balance of comfort, price, and print quality. For everyday use or basic prints, Gildan works well. If you’re building a retail brand or want a softer premium feel, go with Next Level or econscious.
What is Polyester Fabric
Polyester is a man-made fabric that’s known for being strong, durable, and easy to maintain. It’s created from synthetic fibers made through a chemical process, then spun into yarn and woven or knitted into fabric.
Polyester became popular in the 1950s because it didn’t shrink or wrinkle like cotton. Today, it’s a go-to material for athletic wear, work uniforms, and everyday clothing. People like polyester because it lasts a long time, keeps its shape, and dries quickly.
One of polyester’s biggest advantages is how it handles sweat. Instead of soaking up moisture, it moves it to the surface of the fabric so it can dry faster. That’s why it’s used so often in performance gear and sports shirts. If you want to know how that works, check out our post on moisture wicking material fabrics.
Types of Polyester
Polyester can be made in many different ways. Each type has its own texture and purpose. Here are some of the most common ones:
Polyester Jersey Knit
This is the standard T-shirt fabric. It’s soft, lightweight, and slightly stretchy — great for daily wear and custom prints.
Microfiber Polyester
Made from very fine fibers, this type feels smooth and soft. It’s used in athletic gear and loungewear because it’s lightweight, breathable, and quick-drying.
Polyester Fleece
Soft, warm, and cozy. This fabric is perfect for hoodies, jackets, and cold-weather gear.
Mesh Polyester
This version has tiny holes that let air pass through easily. It’s used for sports jerseys, uniforms, and activewear.
Polyester Twill
Twill has a tight diagonal weave that makes it strong and wrinkle-resistant. It’s common in workwear, caps, and durable uniforms.
Polyester Satin
Satin polyester has a shiny finish and smooth texture. It’s often used for fashion items and accessories because of its polished look.
Each type of polyester behaves a little differently. Some are soft and flexible, others thick and structured. The right choice depends on how you plan to use it comfort, performance, or durability.
Polyester T-Shirt Examples
Polyester shirts come in many styles and weights, depending on how you plan to use them. Here are a few common options that fit different budgets and needs:
- Budget: Gildan G420 Adult Performance T-Shirt (5 oz) — a simple polyester tee that’s light, durable, and great for bulk printing or team uniforms.
- Standard: Team 365 TT11 Men’s Zone Performance T-Shirt — smooth, moisture-wicking fabric that’s ideal for activewear and everyday comfort.
- Premium: Bayside BA5300 Unisex Performance T-Shirt (4.5 oz) — made in the USA with a softer hand feel and a higher-quality finish for retail use.
If you’re looking for a strong shirt that dries quickly and holds color well, polyester is a great choice. It works best for athletic wear, outdoor use, and high-performance prints.
Cotton-Polyester Blends
If you’ve ever worn a shirt that feels soft like cotton but dries fast like polyester, you’ve already experienced the best of both fabrics. Cotton-polyester blends combine comfort and performance in one.
These blends are made by mixing natural cotton fibers with synthetic polyester fibers. The goal is to get the softness and breathability of cotton with the strength, wrinkle resistance, and quick-drying power of polyester.
Many brands choose blends because they’re reliable for printing and easy to care for. They hold shape, resist shrinking, and still feel good against the skin.
Why Blends Work So Well
Blends take the best parts of each fabric and balance them out.
- Soft like cotton: Feels natural and breathable.
- Durable like polyester: Resists shrinking, wrinkles, and fading.
- Easy to care for: Washes and dries quickly without losing shape.
- Great for printing: Works well with screen printing, DTF, and heat transfers.
If you print shirts for business or personal use, blends are a safe choice. They look good, last long, and keep their fit wash after wash.
Popular Types of Blends
50/50 Cotton-Poly Blend
Half cotton, half polyester. This classic blend offers comfort, durability, and affordability. It’s soft, holds color well, and is perfect for everyday T-shirts and uniforms.
- Budget: Gildan G800 Adult 50/50 T-Shirt — soft, affordable, and easy to print on.
- Standard: Jerzees 560MR Premium Blend T-Shirt — ringspun fabric for a smoother texture and long-lasting print quality.
- Premium: Alternative 05050BP Keeper Vintage Jersey — soft, stylish, and perfect for retail-quality designs.
A 50/50 blend is great if you want softness with less shrinkage and faster drying than pure cotton.
Tri-Blend
Tri-blends mix cotton, polyester, and rayon. The rayon adds stretch and a silky texture, giving these shirts a lighter and smoother feel. They’re ideal for retail brands or anyone who wants that “vintage soft” look.
- Budget: Hanes 42TB X-Temp Triblend T-Shirt — comfortable and lightweight for everyday wear.
- Standard: Bella + Canvas 3413C Unisex Triblend T-Shirt — silky-soft and perfect for premium prints.
- Premium: Alternative AA1973 Eco-Jersey Crew — soft, drapey, and made with eco-friendly materials.
Tri-blends are known for their softness and stretch. They feel premium and are ideal for brands that want a relaxed, modern look.
CVC (Chief Value Cotton)
CVC fabrics contain more cotton than polyester, usually around 60/40. They feel closer to pure cotton but still resist shrinking and wrinkling. CVC blends are common in premium shirt lines because they’re soft, durable, and easy to print on.
- Budget: Gildan G500 Heavy Cotton T-Shirt (Heather Colors) — affordable option with a cotton-rich blend.
- Standard: Next Level N6210 CVC Crewneck T-Shirt — soft, smooth, and designed for high-quality printing.
- Premium: Threadfast Apparel 104A Blizzard Jersey Short-Sleeve T-Shirt — comfortable and stylish with a soft heather finish.
CVC blends are popular because they feel almost like cotton but last longer and hold prints beautifully.
When to Choose a Blend
Go with a cotton-poly blend when you want balance, comfort and breathability without giving up durability and easy care.
- For printing: Blends are versatile for most methods.
- For casual wear: They feel soft and flexible.
- For businesses or events: They last long and stay looking new.
Blends give you the comfort of cotton and the resilience of polyester, a perfect middle ground that works for almost everyone.
Printing on Cotton, Polyester, and Blends
If you’re planning to print custom shirts, the type of fabric you choose will make a big difference in how your designs look and last. Some fabrics hold color better, while others need special inks or printing methods.
Here’s a quick breakdown of how printing works on cotton, polyester, and blended fabrics and which one might be right for you.
DTF (Direct to Film) Transfers
DTF transfers is one of the most flexible methods available today. It works on any fabric cotton, polyester, or blends.
The design is printed on a film, coated with adhesive powder, then heat-pressed onto the fabric. DTF prints are soft, durable, and long-lasting. They don’t crack or peel easily, even after multiple washes.
Best for: All fabric types.
Tip: Keep designs moderate in size on thin fabrics like tri-blends for the best look and feel.
Screen Printing
Screen printing is one of the most common printing methods. It works best on 100% cotton because cotton fibers soak up ink and hold bright, solid colors. The result is a bold, durable print that feels soft to the touch.
Polyester can be screen printed too, but it takes more care. The heat used during printing can cause dye migration, where the color from the fabric bleeds into the ink. Printers often use special low-temperature inks or additives to prevent this.
Best for: Cotton and cotton-rich blends.
Avoid on: 100% polyester unless you’re using professional-grade inks.
Sublimation Printing
Sublimation uses heat to turn dye into gas, bonding it directly to the fabric fibers. This creates vibrant, permanent prints that won’t fade, peel, or crack.
However, sublimation only works on polyester or fabrics that have a high polyester content (at least 50%). It won’t work well on cotton because the dye needs synthetic fibers to stick.
Best for: 100% polyester shirts or light-colored polyester blends.
Avoid on: Cotton fabrics designs will look faded or wash out.
DTG (Direct to Garment) Printing
DTG printing works like an inkjet printer, applying water-based inks directly onto the shirt. It’s perfect for detailed designs, small runs, and custom orders.
This method works best on 100% cotton because the ink binds naturally to cotton fibers. DTG doesn’t work well on polyester since synthetic fibers don’t absorb water-based ink.
Best for: 100% cotton shirts.
Avoid on: Polyester or blends with low cotton content.
Polyester vs Cotton vs Blends: Comparison Chart
| Feature | Cotton | Polyester | Blends (Cotton + Polyester) |
|---|---|---|---|
| Comfort | Soft, natural, and breathable | Smooth, light, less breathable | Soft with a balanced feel |
| Moisture Control | Absorbs sweat and holds moisture | Wicks away sweat and dries fast | Wicks moisture better than cotton |
| Durability | Can shrink or fade over time | Very durable and holds shape | More durable than cotton, flexible feel |
| Care | Needs ironing, slower to dry | Wrinkle-resistant, quick to dry | Easy to wash and maintain |
| Printing Quality | Great for screen and DTG printing | Works best with sublimation or DTF | Works well with most print methods |
| Eco-Friendliness | Natural and biodegradable | Synthetic and non-biodegradable | Depends on blend ratio |
| Best Use | Everyday wear, casual clothing | Sportswear, performance gear | All-purpose shirts and printing |
Conclusion: How to Choose the Right Fabric
Choosing between polyester, cotton, or a blend comes down to how you’ll use the fabric and what matters most to you.
If you want a soft, natural feel that’s breathable and easy on the skin, cotton is the best choice. It’s timeless, comfortable, and perfect for everyday wear and casual prints.
If you need something durable, wrinkle-resistant, and quick-drying, polyester is your go-to. It’s great for sportswear, uniforms, and active lifestyles where performance matters.
If you want a balance between comfort and strength, cotton-poly blends give you the best of both worlds. They’re soft like cotton, last longer, and work well with almost every printing method.
For most people, the best choice isn’t one or the other it’s the right match for your purpose. Whether you’re printing shirts for your brand, picking blanks for your store, or just looking for a T-shirt that feels great, understanding your fabric helps you make a smarter choice.
