Types of Shirt Material (2025 Guide)

The perfect t-shirt starts with the right fabric — no question about it.
It’s what decides how soft that tee feels, how well it holds up after a few washes, and how good your print actually looks.

You’ve probably seen it all, buttery-soft cotton, slick polyester, and fancy blends that promise “premium comfort.” But when it comes down to it, the right shirt material depends on what you’re using it for: comfort, durability, or print quality.

This article will break down each of the main t-shirt materials including what they are made of, how they feel and what they're best at. If you're looking to print custom t-shirts or you're just looking for a great feeling tee, we'll help you choose the right fabric.

3 Main Categories of T-shirt Material

Choosing the right shirt material sets the foundation for comfort, print quality, and overall satisfaction. Most t-shirts fall into three main categories: cotton,  polyester, and blends. Each has its own strengths, feel, and best-use scenario.

1. 100% Cotton

Cotton is a natural fiber that’s been the gold standard for t-shirts for decades. It’s soft, breathable, and comfortable in nearly any climate. Cotton’s natural feel and versatility make it a favorite for both casual wearers and custom printers.

Types of Cotton

• Ringspun Cotton: Fibers are twisted tightly for a smoother, softer surface, perfect for vivid prints.

• Combed Cotton: An extra refinement process removes short fibers and impurities for a more durable, silky feel.

• Organic Cotton: Grown without harmful chemicals or pesticides, making it a sustainable, skin-friendly option.

• Pima / Supima Cotton: Long fibers provide exceptional softness and strength; considered a luxury fabric.

• Airlume Cotton: A high-grade cotton known for purity and consistency, softer and cleaner than regular cotton.

Common Weaves

• Jersey Knit: The most common weave for t-shirts; lightweight and flexible with a smooth texture.

• Pique: Features a subtle waffle pattern, adding breathability and texture; often used in polos.

Cotton Pros and Cons

Cotton Print Considerations

Cotton is one of the most print-friendly fabrics available. It accepts a wide range of inks and techniques, including DTF (Direct-to-Film) and sprinting.

Because cotton fibers are naturally absorbent, inks and pigments bond deeply with the fabric, creating rich, vivid colors and a smooth, professional finish. High-quality ringspun or combed cotton provides the best print results with long-lasting durability.

DTF transfers in particular pair perfectly with cotton shirts offering vibrant, flexible prints that won’t crack or peel easily.

Cotton Price Point

Cotton shirts range from budget-friendly basics to premium luxury styles, depending on the fiber type and processing.

• Basic carded cotton: economical and ideal for bulk orders or promotional shirts.

• Ringspun and combed cotton: mid-tier softness with reliable print quality.

• Pima, Supima, and Airlume cotton: premium choices offering unmatched softness and durability.

In general, cotton shirts are priced between polyester and blend options, making them accessible while maintaining a premium look and feel.

2. 100% Polyester

Polyester is known for its durability and moisture-wicking performance. It’s a synthetic fiber made from petroleum, which sounds industrial — but don’t let that fool you. It’s a top choice for athletic and outdoor apparel because it keeps the wearer cool and dry.

Moisture-Wicking:

Polyester doesn’t absorb water. Instead, it pulls moisture away from your skin and helps it evaporate quickly. It’s lightweight, wrinkle-resistant, and holds its shape after multiple washes.

Types of Polyester

• Basic/ Standard Polyester: Affordable, durable, and commonly used for uniforms or athletic tees. It’s not the softest, but it’s tough and gets the job done.

• Microfiber Polyester: Made with super fine fibers for a smoother, softer texture — it can actually feel similar to cotton but dries way faster.

• Performance Polyester: Engineered blends that mix polyester with stretch or snag-resistant fibers for better comfort, breathability, and movement. You’ll find this in high-end activewear and premium tees.

Polyester Pros and Cons

Polyester Print Considerations

Printing on polyester can be tricky. The fabric’s slick surface doesn’t absorb ink like cotton does. Dye-sublimation is the best option here because the dye actually becomes part of the fibers, giving you bright, fade-proof prints that’ll never crack or peel.

DTF transfers also work great on polyester,  the adhesive bonds cleanly without the bleeding issues you get with some other methods. Just avoid screen printing or DTG (direct-to-garment) on pure polyester unless you’re using specialty inks, the results can be inconsistent.

Polyester Price Point

Polyester t-shirts are usually budget-friendly, especially the standard types. If you move up to microfiber or performance polyester, you’ll pay a bit more but you’re getting next-level comfort and durability. It’s a solid pick when you need shirts that last, hold shape, and dry fast.

3. Blends

Blends are where comfort meets practicality. They mix two or more fibers to get the best of both worlds usually cotton for softness and polyester for strength. You’ll see blended fabrics everywhere in the t-shirt world because they hit the sweet spot: soft, durable, low-maintenance, and great for printing.

Instead of choosing between natural and synthetic, blends give you a bit of both which makes them one of the most versatile fabric types out there.

Popular Types of Blends

• 50/50 (Cotton/Polyester): This is the classic t-shirt blend — half cotton, half polyester. The cotton keeps it soft and breathable, while the polyester makes it more durable and less likely to shrink or wrinkle. It’s that “everyday tee” combo you’ll find in tons of retail and promo shirts. It’s affordable, holds its shape, and prints cleanly without the headaches of 100% polyester.

• Tri-Blends (Cotton/Polyester/Rayon): Tri-blends step things up a notch. By adding rayon into the mix, you get a shirt that’s super soft, lightweight, and drapes perfectly. It’s got that broken-in, vintage feel that’s crazy comfortable right out of the box. You’ll often see tri-blends with a subtle heathered look, a textured mix of fibers that gives the shirt personality. These are a favorite for retail brands and anyone chasing that “premium tee” vibe.

• Performance Polyester: CVC means the shirt is mostly cotton (usually around 80%) with a bit of polyester for added structure. You still get the breathable, natural feel of cotton but with less shrinkage and a cleaner fit. It’s a great option if you want the comfort of cotton with just a touch of polyester’s durability.

• Other Common Blends

  • Cotton/Spandex: Adds stretch and bounce-back, perfect for fitted or athletic styles.

  • Polyester/Spandex: Maximizes flexibility and moisture control, great for performance or workout gear.

  • Rayon/Viscose Blends: Smooth, lightweight fabrics with an easy drape, often used for fashion-forward or women’s styles.

Blends Pros and Cons

Blends Print Considerations

Blends are printer-friendly especially for DTF. The film adheres smoothly across both the cotton and polyester fibers, giving you crisp, long-lasting prints. Screen printing works too, but you’ll want to use inks made for blends to avoid dye migration (when the polyester color seeps through the ink). DTG printing, on the other hand, isn’t ideal, it can lead to faded or inconsistent prints.

Blends Price Point

Blends cover a wide range of price options. The basic 50/50 blend is one of the most affordable, making it great for bulk orders or merch drops. If you’re after something softer and higher-end, tri-blends and CVC shirts are worth the extra few bucks. They feel better, fit better, and elevate the overall look of your print.

What Shirt Material Is the Softest?

If softness is what you’re after, tri-blends take the win — hands down.
They mix cotton, polyester, and rayon, and that combo hits the sweet spot between silky, stretchy, and feather-light. The rayon adds that smooth, lived-in drape, while the cotton keeps it breathable and the polyester helps it hold shape.

You know that broken-in shirt that feels perfect the first time you wear it? That’s usually a tri-blend.

But they’re not the only soft ones out there. Combed and ringspun cotton can feel buttery smooth, especially in higher-quality tees. And if you’re into eco-friendly options, bamboo viscose and modal blends are insanely soft, they’ve got a cool, silky texture that’s perfect for everyday comfort.

If you want that “favorite shirt” feel right out of the bag, go for tri-blends or premium combed cotton. They’re soft, lightweight, and they only get better with wear.

Specialty Fabrics

While cotton, polyester, and blends cover most t-shirts out there, a new wave of specialty fabrics is making big moves in the apparel world. These materials stand out for their unique textures, eco-friendly options, and high-end feel. They’re great for customers who want something different — softer, greener, or just plain better.

Here are a few popular specialty fabrics worth knowing:

Rayon / Bamboo Viscose

Both rayon and bamboo viscose are made from plant-based fibers that go through a refining process to create super soft, smooth, and breathable fabrics. They have a cool, almost silky feel and a light drape that makes them perfect for premium or fashion-forward tees. Bamboo, in particular, is popular for being naturally moisture-wicking and eco-conscious, making it a favorite among sustainable brands.

Linen

Linen comes from flax plants and has that distinct, slightly textured look that people love. It’s breathable, durable, and naturally cool to wear, basically built for warm weather.
It wrinkles easier than cotton, but that’s part of its charm. Linen shirts have that laid-back, classy vibe that works for beachwear, summer collections, or anything casual and timeless.

Specialty Blends

Fabric makers are constantly experimenting with new blends to meet different needs — from recycled or upcycled materials for sustainability to performance blends designed for flexibility, stretch, or sweat resistance.
Think of these as the “next-gen” t-shirts: eco-friendly, moisture-wicking, wrinkle-resistant, and made to perform without losing comfort or style.

Fabric Weight

When you hear people talk about t-shirt “weight,” they’re talking about fabric density — how thick or heavy the shirt feels. It’s usually measured in ounces per square yard (oz) or grams per square meter (GSM).

Fabric weight doesn’t automatically mean quality or durability — it just tells you how the shirt will feel and wear. Here’s the breakdown:

Lightweight (3–4 oz)

Lightweight fabrics are soft, thin, and breathable often used in tri-blends or 50/50 blends. They’re great for fitted, fashion tees or summer wear. Because they drape nicely, they work well for layering or casual comfort.

If you’re printing big, solid designs, just be aware that a lighter shirt can feel a bit heavier where the print sits.

Standard (4–5 oz)

This is your “everyday” t-shirt weight  durable enough to hold up but still soft and flexible. Most retail and promotional shirts fall in this range. It’s the perfect balance of comfort, structure, and versatility for most printing projects.

Heavyweight (6–7 oz+)

Heavyweight shirts feel thicker, warmer, and more substantial. They’re made mostly from cotton or cotton-heavy blends and are built for durability.
These are great for cooler weather, workwear, or anyone who likes that solid, structured tee that holds its shape wash after wash.

Choosing the Right Weight

When it comes to fabric weight, here’s the quick cheat sheet:

• Lightweight: Best for hot weather, layering, or a relaxed fashion fit.

• Medium weight: Your go-to for daily wear and printing versatility.

• Heavyweight: Perfect for durability, structure, and cooler climates.

And if you’re printing with DTF transfers, medium-weight shirts usually hit the sweet spot, they hold color beautifully, don’t bunch up under the press, and keep their shape over time.

The Bottom Line on T-Shirt Fabrics

Picking the right shirt fabric isn’t just about what looks good, it’s about how it feels, how it wears, and how it prints. The best shirts balance comfort, performance, and durability while still giving you that clean, pro-quality print.

Once you understand the difference between cotton, polyester, blends, and specialty fabrics, you can match the right shirt to every job from soft retail tees to long-lasting workwear. The more you know your materials, the easier it is to deliver shirts people actually want to wear again and again.

At DTFVirginia, we’ve tested just about every kind of shirt and print combo out there. We know what holds color, what feels right, and what lasts. So whether you’re printing for a business, a brand, or just for fun, start with a quality shirt and we’ll make sure your design looks as good as it should.

Print smarter. Choose better materials. Create shirts people will actually love to wear.